In life, it seems we sometimes start something with absolutely no idea of the sheer scale of the endeavour. This bus conversion definitely falls into that category.
In our last post back in December 2025, we thought we would be close to wrapping things up by January 2026. Well, it is now October 2026, and we are still not quite there yet.
Progress has been made, though—honestly! Here is the rundown of what has been checked off the list.
Battery Box
We fabricated and mounted the battery box for the lower battery. I initially had this grand idea that we might fit both batteries under the floor, but reality set in quickly—space was just too tight. We ended up with one battery mounted under the floor (designed so it drops out cleanly from underneath if needed) and the second battery positioned at floor level inside.
Skylights & MaxxFan
We installed three skylights and one MaxxFan. Getting standard RV fittings onto a bus roof is always a bit of a headache; they are engineered for dead-flat RV roofs, whereas a bus has compound curves, crowns, and structural ribs to navigate. To solve the sealing issue, I ended up building custom timber plinths to create solid, flat mounting faces for each opening.
I must take some photos of the now finished roof …
Windows & RV Entry Door
Next up was installing two Seitz double-glazed campervan windows, complete with integrated blinds and flyscreens. We initially considered retrofitting blinds to the original bus glass, but double glazing made far more sense for thermal performance and sound deadening. Getting them framed square, seated, and genuinely watertight took a fair bit of wrestling, but they are in.
We also cut out the original folding bus door and replaced it with a dedicated RV security door. Having an integrated flyscreen means we can keep the main door wide open for cross-ventilation on warm days without inviting every bug in the area inside.
Framing for Spray Foam
For insulation, we committed to closed-cell spray foam. That meant completing all internal wall, ceiling, and partition framing beforehand so the foam could expand directly behind the framing against the steel skin.
Insulation methods in the camper community are always heavily debated, but closed-cell provides an unbeatable vapor barrier and rigidity. The framing stage turned into an epic undertaking—possibly slightly over-engineered, but the goal is a bus that stays warm and dry in winter, cool in summer, and solid for years to come.
Next post will show the finished outcome of the spray out.
Electrical & Solar Panels
First-fix wiring is finally complete. The critical catch with spray foam is that once it goes in, running another wire through the wall cavities becomes a massive chore. Every primary circuit, DC drop, sensor lead, and AC run had to be completely mapped and routed beforehand.
Mounting the solar panels presented the same curved-roof challenge as the skylights. I fabricated custom mounting brackets bolted securely through the roof structure, which the panel brackets then mount to. This keeps the panels level and allows individual panels to be unbolted and serviced later if needed.
The boys came over to help hoist the heavy panels up onto the roof, and we made the most of the extra hands by getting the awning mounted at the same time.
New Tyres
We had six new Yokohama tyres fitted by the team at Wheel Max— outstanding service. The old tyres still had legal tread depth, but they were well past their expiration date and starting to show sidewall cracking. Safety first.
Swivel Seat
The floor reinforcement plates for the passenger seat mount and certified seatbelt anchors are in place. Just a few final structural details to tie off before the certification sign-off, but like everything else on this build, getting it right has been a real mission.
The idea .. seat on the left .. the mounting plate for belts on the right .. final images will be in a few posts time – but its coming along …
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