Do's and Don'ts of Bus Conversion Design

[dtcerrato]

I totally agree with BW on keeping panels inside for easy inside resetting especially in inclement weather and again on using the bus during your build. btdt

[luvrbus]

I would just like to see the buses finished more get set to bus scrap yards than the ones finished by far.I bought a MCI for friend that was for sale,the owner paid 15k for the bus and purchased a new 12.k generator with inverters,water heater and every thing to finish and gave up.I paid him less than what he paid for the bus shell for all of it.LOL I seriously doubt my friend will finish it he may surprise me but I have my doubts,it is his bus now so I am not going to worry to much       

[kyle4501]

A real, practical listing of the cost involved to convert one. (ranging from DIY to paid shops).

It saddens me to see so many people who don't realize how much it costs to service a heavy vehicle.

Parts availability will be an issue for some models.

Oil changes are in gallons, not quarts.

One can easily spend over $500 for a complete set of new lugnuts - now add wheel studs . . . Not to mention brakes & tires.

[luvrbus]

A real, practical listing of the cost involved to convert one. (ranging from DIY to paid shops).

It saddens me to see so many people who don't realize how much it costs to service a heavy vehicle.

Parts availability will be an issue for some models.

Oil changes are in gallons, not quarts.

One can easily spend over $500 for a complete set of new lugnuts - now add wheel studs . . . Not to mention brakes & tires.

Changing the fluids in the fan,engine,transmission,generator and engine and generator antifreeze with filters I am at 1200 bucks  material only plus 2 days labor and 1 trip to the ER for 5 stiches  on my coach .Cummins $500.00 bill for oil,filters on the engine and generator is looking good right now   

[Jim Blackwood]

And, don't disable the coach during the build. Nothing keeps the support for the dream alive better, than using the coach.

I just picked up a pair of new batteries, windshield is replaced, a little work on the leveling system and I can put insurance on it and get it titled and licensed. Toilet was delivered today, sink won't be here for a couple or three weeks, reconditioning the range now. Then I should be able to tick all the boxes for an RV title. Realistically it'll be at least a month or two and may be next spring before a maiden voyage can happen. By then I should have the waste tanks done as well. I haven't moved it for awhile. But there isn't a whole lot of driving I can do before I have tags. There is a little catch there in the RV title requirements.

Jim

[epretot]

Surround yourself with others who know more than you.

This forum is a great start. However, I have a good mechanic that allows me to bounce ideas off of him

A friend of mine who is a welder at GE and basically reminds me of MacGyver.

Two electricians that make my head hurt when they are talking to each other about MY bus.

And another friend who poo poos my bad ideas (he has a bus too).

[Tedsoldbus]

I've had 4 RVs, but this our first bus. We have it almost a year, and boy are they different. I ALWAYS seek counsel from the two old bus guys we know from Rita's dad's bus days. They had shops and were no kidding real bus mechanics for a living. I hope they don't die....
Some conversions like Jim Blackwood's won't be done for a while, but run everything you CAN once a month. Old bus guys tell me "Get it on the road once a month if it runs, even if it is just for an hour".
Run EVERYTHING. I check engine oil and then start it. I start the generator and while rolling we run the one bus heater (propane), run the two roof airs at the same time. Run the dash heat and then air. Turn on the water heater. Run both water pumps in all spigots. Doing more than just starting the engine (go somewhere) also gets all the engine stuff up to pressure and temperature. It exercises the wheel bearings, tires, air bags etc etc The old guys tell me to basically try to run everything you would use on a long trip. Check headlights and blinkers.
On these short runs, I have discovered a leak here, an indicator light for the H/W heater burned out. A leaky water line that runs from engine to dash that we replaced. When I get home and engine is hot, I check trani fluid.
So.....I really do feel like I could fire it up today and head for Montana. Something will break, but it won't be 7 things. As you convert, keep trying exercising what you think is done. The bonus is that when the conversion IS done, you will be used to running all this stuff!
That is advice from two bus mechanics. (I am not one....). But is has served me well. Both mechanics said "Worst thing for these old buses is to sit.".

[chessie4905]

I can see this on the Prevost conversion  craze.  People are doing whatever in the financing department to get one. THEN realize insurance, fuel costs, maintenance costs are more than they can afford. Expect to see many more for sale in a couple of years. Problem I can see is first to save money, they will avoid necessary service on them, like not changing oil, etc. Amazing how many you see for sale with relatively low miles with "new engine installed".

[luvrbus]

All buses for sale have new engines with less than 10,000 miles you notice that John but fact is buses are killers on engines they just don't last long back there.Four strokes last longer when you get around 600,000 on series 60 in bus you better start saving your money the, 2 strokes are usually gone at 300,000 miles

[windtrader]

Gary is gonna shoot us and dump our bodies in the desert for scaring off all potential tire kicking busnuts. Many, including me started off with the dream of DIY converting a bus into a custom RV. For those doing research soon find out how much of everything it takes to do one A to Z. There are a few unicorns that have the perseverance and tanacity to do it. Jim is a regular here and makes regular progress but still a long way from realizing his vision. We all hope he gets it done and life doesn't throw a curve. Still, for nearly all, do some deep soul searching, wake up, then just buy an already running converted bus and go on a road trip.

DIY or bought you can't escape ongoing costs. Even knowing what was involved upfront, it still is eye opening and wallet-busting to deal with keeping it on the road. Yes, everything is gallons, not quarts. Doing a full tread upgrade is as much as buying a commuter car for the college-bound kid. Parts and service are a hunt. The list goes on but this is going OT.

[luvrbus]

Buses are not for everyone for sure

[chessie4905]

I'm  talking about Prevost conversions that aren't that old or high of mileage. Run low on oil or overheated seems common. those 8V-92's on high horsepower settings seem to be hard on bearings.

[Melbo]

We started traveling in our bus in 2004.  We have redone many parts and one complete clean up.  One new motor and trans (by B&B) and use it three to four times a year.  When we start driving we take note of how long we travel before "The List" starts.  Sometimes before we get out of town and sometimes after we have traveled for a  day.  We kind of have a permanent list that is really a "Wish List" and sometimes things get finished from that list but the other list is for things that need to be secured changed and added.  Drawers and cabinets that don't stay closed window coverings that rattle broken window latches etc.  We do once a year annual maintenance.  Engine oil trans oil generator oil check all batteries complete lube and adjust the brakes (also adjust brakes between MAJOR trips).  We use tire monitors and battery voltage monitors.  We have fun as long as we use it and we add and change as we feel the need.  We don't have a stove and we don't use propane.  We had a smooth electric cooktop we were going to install and after storing it for three or four years we sold it.  For heat we use electric cube heaters and thermometer and compass.  If it gets cold where we are we need to head home or go south.  Just our way but that is the thing about a bus conversion.  Do what works for you and be sure to get it on the road regularly.

Melbo

[Jim Blackwood]

>...be sure to get it on the road regularly.

With that thought in mind, I've gotten back on the control wiring for the leveling jacks. I have the HVAC ducts off and that is a good place for the wiring and I have a 100 ft roll of extension cord cable to connect the 3 phase motors to the controllers up front. The 3 controllers (VFDs) will fit snugly under the driver's armrest, a nice convenient spot, with 3 of my spare inverters nearby and a couple of bubble levels. I need current limiters to complete the picture and connect everything up. Can't move the rig until the jacks can be retracted.

As for my perseverance, here's a taste. First my personal vehicle, a 1971 MGB that I've owned since 1978 or 79:
http://forum.britishv8.org/read.php?2,274

And next a project car I spearheaded:
http://forum.britishv8.org/read.php?2,166

Be forewarned though these threads cover a lot of years and a great number of posts. Something like 35 pages and 132 pages respectively.

I didn't undertake my bus conversion lightly. It started as a 5 year project and I do still have some chance of making that goal.

Jim

[usbusin]

Jim, the 2nd link is the same as the 1st.

Quite a project car you have there! 

My first car was a 1948 MGTC right hand drive.  My number 2 son has my dads Jaguar XK120 FHC.  In 1959 my dad did 140mph at Bonneville with the Jag.  Drove it up and back with averages of over 100mph average between towns in Nevada.  Lovelock to Winnemucca; Winnemucca to Elko.  No speed limits in those days.