2013 Chevy Express Thomas Minotour Build - 4 Window, 6.6L Duramax

[njl1031]

Hey folks!

Going to be starting this build in a few weeks and plan to document my progress here. I've started gutting it, but dropped it at my mechanics for a few weeks to get it converted to 4x4. This will be the biggest cost of this build, probably more than the rest of the build, and something I've been so excited about and saving for for a while!

The bus is a 2013 Chevy Express 3500 with a 6.6L Duramax Diesel engine, a 6L90 (6-speed) transmission, about 95,000 miles on it, and a Thomas Minotour body. I stalked the interenet for several months before jumping for this one for $7000. I really wanted a diesel with a beefier transmission, and the low miles and low rust convinced me to buying a newer once, which I immediately payed for with some emissions issues, but so be it.




The 4x4 conversion is being done by a mechanic I know back in Colorado who runs a 1-man shop and loves doing his own custom 4x4 projects. A conversion like this could be done by a DIY-er but without a garage and a lift it would be a huge PITA. A lot of parts are coming rebuilt/salvaged, sourced either by my mechanic, or by Timberline Supply in CO. Those are the guys that put together the conversion "kit". They custom fab a few mounting brackets that are needed, and compile a list of other parts needed for your to source yourself, or get through them. Parts for this conversion are $5k-$10k and it's 35-55 hours of labor if I remember correct (so another $5k+).

The inside is a mess right now. I took out the benches (me pictured under the bus, frustrated that my friends up top are posing for photos instead of hold a wrench to the bolts). I've removed some of the interior trim and walls/ceiling panels.

Once I get it back from my mechanic I'll be doing a roof raise and window delete, cheap shitty paint job, and then racing the winter weather to get a basic interior to live in while replenishing my bank account for a more gradual full interior build.

I'll post some floor plan, electrical, and plumbing concepts later, would appreciate any critique of them.

Thanks for getting this far, I'm super excited to share this build process!

[bp3.0]

Originally Posted by njl1031

Hey folks!

The 4x4 conversion is being done by a mechanic I know back in Colorado who runs a 1-man shop and loves doing his own custom 4x4 projects.

Ooooh, a 4x4 conversion. I am envious of you. I look forward to seeing what you do with it! Seems like a decent starting platform to me.

Jim

[AlphaHare]

I'll be interested to see how this turns out! Where do you ski?

This is probably too much for me. But I am thinking a Weldtec lift and spring kit, and a rear locker. That's probably as wild as I want to go.

[nikitis]

Just one suggestion.

If you are going to be living it out in the Winter, after the roof raise I'd prioritize the insulation next cause you're gonna freeze in it otherwise.

[njl1031]

Well I realized that my photos didn't add to my post, I'm still learning how this works. Let's see if it works this time.


Here's the bus pre 4x4 conversion, and me undeneath working on bench removal while my friends inside are clearly not holding a wrench to the bolt heads








And here's the interior that we're working with, total mess.

[njl1031]

Originally Posted by AlphaHare

I'll be interested to see how this turns out! Where do you ski?

This is probably too much for me. But I am thinking a Weldtec lift and spring kit, and a rear locker. That's probably as wild as I want to go.

I've been up in Breckenridge the last two winters, but I plan to go elsewhere this winter, maybe Taos. I was living in my converted Chevy Express van in Breck, but it's just too van unfriendly for me there.


I ran a limited slip on the old van, and plan to run it on this bus as well. The Detroit TrueTrac. It worked amazingly well in snow and mud, and decently in sand too depending on how deep it was because of the heavy vehicle. Lots of research convinced me to go with that over a full locker because of on road handling issues.

[njl1031]

Originally Posted by nikitis

Just one suggestion.

If you are going to be living it out in the Winter, after the roof raise I'd prioritize the insulation next cause you're gonna freeze in it otherwise.

Yes of course! That's a given in building a simple interior for now. I'll be adding 3" of XPS board on the floor and ceiling, and 2"-3" on the walls, and adding plywood sheathing all over. I'll have my floorplan decided so I'll lay the wiring already as well so I can hook up my diesel heater and a basic water system for the time being.

[BMWNJ]

Ohh a 4x4 Chevy bus! now there's something you dont see too often! I'm looking forward to following along.

[AlphaHare]

Originally Posted by njl1031

I've been up in Breckenridge the last two winters, but I plan to go elsewhere this winter, maybe Taos. I was living in my converted Chevy Express van in Breck, but it's just too van unfriendly for me there.

Thanks for the locker advice!

We did Taos three years ago - rented a place in town for two weeks. Awesome town, pretty chill in the winter, and a bazillion places to put a van, including a van/rv specific lot at the ski area. Big hill - great tree skiing. Take a loop around to the east as well on 64 and 38. Red River looks like fun, but haven't skied there (yet.) Go west over the gorge and you have all the room in the world....