The Ultimate Guide To Converting A Bus Into A Camper

Converting a bus into a camper is a complex but rewarding process. It involves several steps, from initial planning and research to demolition, construction, and finishing touches. The first step is to purchase a suitable bus, such as a decommissioned school bus or a shuttle bus, which can be found at auctions or online. Before beginning any work, it is essential to address any mechanical issues and ensure the bus is in good working condition. The next step is to remove all interior components, including seats, floor, wall, and ceiling coverings, and any unnecessary fixtures. After addressing any structural concerns, such as water damage or rust, the windows should be sealed to prevent leaks. Choosing the right insulation is crucial, followed by the installation of furring strips and additional insulation. This is when the real building begins, including the installation of electrical, plumbing, and propane systems, as well as the construction of furniture and interior walls. The final steps include painting, installing appliances, and testing everything to ensure it works correctly. While challenging, converting a bus into a camper offers a unique and satisfying experience, resulting in a mobile home tailored to your specific needs and preferences.

Buying a bus

The first step in converting a bus into a camper is, of course, buying a bus. You can find decommissioned school buses at auctions for somewhere between $3,000 and $6,000, or on platforms like Facebook Marketplace. On the site Northwest Bus Sales, they can go for around $15,000. The cost depends on whether you are getting a short or long bus and how new the bus is.

When buying a bus, it's important to do your research. Watch videos, talk to people with firsthand experience, and tour a bus conversion. It's also a good idea to learn some basic electrical, plumbing, automotive, and external power skills, as this will save you money in the long run.

When buying a bus, it's crucial to consider what you need in an RV. If you plan to spend a lot of time in it, you may want a larger, transit-style bus. However, keep in mind that large buses can be difficult to maneuver and more costly to fill up with gas. If you plan to use your converted bus for shorter, spontaneous trips, a conventional bus with less passenger room may be a better option.

Other factors to consider when buying a bus include the engine, transmission type, year, and mileage, as these will impact the life cycle of the bus. It's also important to make sure the bus is in good condition and has no major mechanical issues.

Once you've found the right bus and done your research, it's time to start the conversion process.

Demolition and design

Demolition

Demolition is the first step in converting a bus into a camper. It involves removing all the interior components, such as seats, floor coverings, wall coverings, ceiling coverings, and any other unnecessary items. It is important to carefully plan the demolition process to avoid damaging any components that you intend to reuse or replace. Basic tools such as an angle grinder, pry bar, screwdriver, and drill will be needed for this process.

Structural Repairs

Before beginning the rebuilding process, it is crucial to address any structural issues with the bus. This includes checking the subfloor for water damage or holes and repairing or replacing metal supports that show signs of rust. It is also recommended to paint exposed metal with rust-preventing paint to ensure the longevity of the vehicle.

Sealing Windows

The next step is to seal the windows to prevent leaks. This is done by spraying water on the windows from the outside while someone checks for leaks inside the bus. All windows should be resealed, even if no leaks are found. The sealing process involves removing the windows, scraping off old sealant, and replacing it with new butyl tape and weather stripping.

Choosing Insulation

There are various types of insulation to choose from, such as Polysio foam board, rigid foam insulation board, or fiberglass. The insulation should be installed in the wall cavities and glued down with industrial-strength construction adhesive.

Subfloor Installation

The subfloor is typically made of plywood and is installed over the insulation. Tongue-and-groove plywood is recommended for ease of installation. Sanded plywood is also a good option, with thicker plywood being preferable but more expensive. The subfloor will need to be cut and trimmed to fit the bus and secured with wood-to-metal screws.

Framing and Utilities

The next step is to build the frame for the walls, ceiling, and floor using plywood. This involves creating a frame, adding insulation and wiring, and then building the actual walls, ceiling, and floor. It is recommended to build the ceiling first, followed by the walls, and then the subfloor and final flooring. During this process, it is important to account for the placement of the bed frame, cabinets, and bathroom walls.

Plumbing and Electrical Systems

At this stage, you should also plan and install your plumbing and electrical systems. This includes installing water tanks, marking fixture placements, and running wires and pipes through the floor and ceiling. It is important to consult with professionals if you are unsure about the plumbing and electrical work.

Design and Furnishing

Finally, you can begin designing and furnishing your new camper! This includes installing appliances, cabinets, and furniture, as well as adding personal touches to make it feel like home. Remember to test all your appliances and systems to ensure they are functioning properly.

Converting a bus into a camper is a complex and time-consuming process, but with careful planning and execution, you can create a unique and comfortable living space.

Insulation and flooring

Insulation is one of the most important steps when converting a bus into a camper. Without it, you will be very cold in the winter and hot in the summer. It is also important to insulate your bus to reduce noise from the road.

Before installing insulation, you will need to completely gut the bus. This involves taking up any existing floor, removing any lining, and patching up any rust.

Soundproofing

Before installing any insulation, it is a good idea to add soundproofing to the walls and roof of the bus. Soundproofing will make a huge difference in reducing the noise of rain on the bus's metal roof. Soundproofing materials include sound deadening strips, which are easy to apply and cut to size.

Insulation

There are several options for insulating the walls and ceiling of the bus. One popular option is to use foam insulation board, such as polyiso board (PIR), which has a high R-value (a measure of its ability to resist heat transfer) and is fire-resistant. Another option is to use recycled bottle wool or fibreglass to fill in the gaps between the metal beams. When choosing insulation, it is important to consider not only the R-value but also the environmental impact and health risks of the material.

Vapour Barrier

Once the insulation is in place, it is a good idea to cover it with a vapour barrier to prevent condensation from reaching the insulation. A vapour barrier can be made from a material such as silver bubble foil insulation, which can be attached to the insulation with spray adhesive and taped at the seams with aluminium foil tape.

Subfloor

The next step is to install a subfloor. This will provide a stable base for your finished floor. First, fill in any low spots or corrugations in the metal floor with sheets of minicell foam or a product like Bedrug, which is a plastic floor mat with foam backing that fills in the corrugations. Then, cut and fit pieces of foam insulation board, such as 1" thick XPS foam, into the floor. Make sure to leave a slight gap around the perimeter of the floor to prevent the insulation from rubbing against the metal and squeaking. Finally, cut and fit pieces of plywood over the insulation to create the subfloor.

Finished Floor

The finished floor will be the surface that you walk on and should be durable, waterproof, and easy to clean. Popular options for the finished floor include sheet vinyl, luxury vinyl plank (LVP), cork, rubber, and linoleum. Avoid solid wood, laminate flooring, foam, and tile, as these are not durable or waterproof enough for a camper bus. To install the finished floor, cut the flooring material to size, leaving a gap around the perimeter, and attach it to the subfloor with adhesive. Be sure to caulk the edges to create a waterproof seal.

Systems and utilities

Now that you've got the layout of your bus camper, it's time to start thinking about the systems and utilities you'll need to install. This includes things like plumbing, electrical, and gas systems. Here are some tips to help you get started:

• Plumbing: You'll need to decide on the type of plumbing system you want to install. The most common option is to have a freshwater tank installed for cooking, cleaning, and drinking. This will require a grey water tank to catch the wastewater. You'll also need to decide on the type of toilet you want to install. Some people opt for a black water tank, while others prefer a composting toilet or cassette toilet.
• Electrical: Most people choose to power their bus campers with a generator, which can be battery, gas, or solar-powered. If you plan to install solar panels, the roof of your bus provides a lot of space for them. It's important to consider the electrical demands of your appliances and ensure your batteries are high-quality and can meet those demands.
• Gas: For cooking, a propane stove cooktop is a popular choice. Keep in mind that you'll need to store a few propane tanks on hand.
• Heating and Cooling: There are a few options for heating your bus camper. Propane and diesel are effective but can be expensive. Wood furnaces are cheap to run, but you'll need to figure out a way to funnel out the smoke. Electric heating is also an option, but it may not always be available. For cooling, consider installing roof vent fans.
• Water Storage: When it comes to water storage, most people opt for a freshwater tank. The size of the tank will depend on your personal needs, but most RV owners feel comfortable carrying around 100 gallons of water. It's best to store the water tank in the undercarriage of your bus rather than on the roof.
• Insulation: School buses don't have great insulation, so you'll need to add some to maintain a comfortable temperature inside your bus camper. There are a variety of insulation materials to choose from, including XPS Rigid Foam, Closed Cell Spray Foam, Sheep Wool, Fibreglass, EPS Foam, and ISO Foam. Make sure to insulate the walls, ceiling, and floor, and consider double-paned windows to help regulate the temperature.
• Lighting: School buses typically don't have great lighting, so you'll need to install some additional lights. Consider adding extra lights around the exterior for when you're travelling or staying in rural, darker areas.
• Curtains: To block out light and help regulate the temperature inside your bus camper, consider installing two types of curtains. Thin, white curtains can be pulled across the windows during the day to let in light while blocking the view, while thicker curtains can be used to completely block out the sun or keep the heat/cold out.

Testing and finishing

Once you've built your furniture and installed your systems, it's time to install your appliances and test everything. Make sure your stove burners fire up, that your hot water line is actually hot, that your vent fans all turn on, and that your lights work as expected. Don't wait until you're ready to take your first trip to realise something isn't set up quite right. Catching issues early will save you plenty of headaches down the road.

The next step is to install the floor. If you're using Luxury Vinyl Planks, wait until the very end to install your floor. These floors are designed to expand and contract with changing temperatures. If you put your cabinets directly on top of them and screw down into these planks, they'll be unable to move, and you will likely have issues with your floor in the future. Even if you're using a different kind of flooring, your bus will be a workshop until the build is mostly done. There will be screws and nails and wood splinters on the floor, and all of these things can cause a lot of damage to a brand new floor.

Now, you're almost done. You probably have some interior design to do, and maybe some cushions and curtains to sew. But believe me when I say that when you've arrived at this step, all of the hard stuff is over. Rejoice in your amazing accomplishment!

A build is never truly done, though. It's a lot like owning a house—there's almost always something that needs a little bit of fixing. But the big benefit of having done a build yourself is that you know how every component should work, which makes repairs a lot easier.

Frequently asked questions