Buyzen Bus Build: 2013 Chevy Express Shuttle

Buyzen

Advanced Member
Joined
Nov 26, 2023
Posts
51
Location
Regina, Saskatchewan
Hellooo everyone,

In a week from now last year I bought my bus and since then the progress has been slow but steady! She's a 2013 Chevy Express 3500 gas with the 6.0 Vortec and about 21.5 feet but shy of 24 feet with the motorcycle carrier and bush bar. Purchased on Vancouver Island, Canada and was previously a Vancouver city transit bus.

In no particular order I have:

-added a rear tow hitch & motorcycle carrier
-mounted a spare tire under the rear
-added a heavy duty bush bar on the front
-new all terrain tires on the rear
-new rear shocks, front tie rods, alignment, etc.
-replaced the steering wheel
-full deconstruction inside (wheelchair lift, seats, floor heater, plexi supports, old fibreglass insulation, most wall and ceilings panels, old radio, etc.)
-made room for a passenger seat up front
-plugged all seat bolt holes in the floor from both inside and outside (didn't need to rip up my flooring)
-Put over 6000kms on the bus
-and probably a few other odds and ends

Overall I've done the necessary (to me :rofl:) things on the outside including most importantly making sure the bus is mechanically sound and solid first before starting my build inside.

Now that she's solid and deconstructed, as spring approaches I'm preparing to enter the building phase of my bus inside. I've been doing tons of research on here and YouTube university over the winter for what I want, learning from others, etc. To keep it simple, rustic and humble with comfortable basics including my must have wood stove.

With music and DJ'ing being a big part of my life and incorporating that into my build, I will be soundproofing all the panels before adding insulation in. (I'm not interested in spray foam)

I purchased a product similar to Kilmat but a thicker hybrid version (200 mil vs Kilmats 80 mil) and made with 3 different layers including MLV called Siless. Does anyone have any experience with these stick on products on a fibreglass shuttle shell? I assume it will adhere the same as to steel. I know not every part of the panel is necessary to cover (although car enthusiasts do that) but I might spend the extra $$ to full cover for the extra small thermal and sound benefit.

Amazon Link to the product: https://www.amazon.ca/dp/B0B6JKF9SC?psc=1&ref=ppx_yo2ov_dt_b_product_details

Anyhow, just wanted to introduce my bus and start a build thread to show progress along the way. The bus will be built to handle the Pacific Northwest and temperate winters of the west coast in Canada but I don't have the headspace nor the floorspace to insulate for very cold winters. Travelling or living in the bus in harsh temperatures doesn't interest me much and I'd rather travel to the warmer west or snowbird south in winter.

Thanks for stopping by and I look forward to sharing the progress! :Thanx:
 

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do you have any pics of how you mounted the spare tire underneath
 
do you have any pics of how you mounted the spare tire underneath

Hopefully these help. I just had a fabrication shop come up with a simple solution and weld a giant bolt to the frame with a steel plate and nut that holds the tire up. It's very strong and has been under there for almost a year down bumpy forestry mountain roads.
 

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do you have any pics of how you mounted the spare tire underneath

Hi everyone. Been working on the bus here and there... slow and steady and just finished most of the main soundproofing today. I used a product called Siless Hybrid 3 in 1 which is a combination of closed cell foam, butyl rubber and mass loaded vinyl with an adhesive backing. It's been very easy to work with.

I'm aware covering the entire surface isn't totally necessary for soundproofing but after sooo much research on this hotly debated topic I decided to follow my gut and do what most car enthusiasts do which is cover as much as they can. I also wanted to benefit from whatever it would give me for heating and cooling barrier as I don't have much headroom in this bus for very thick insulation and will be relying on my wood stove and diesel heater.



https://www.amazon.ca/dp/B0B6JKF9SC?ref=ppx_yo2ov_dt_b_product_details&th=1

Next steps for me now are to figure out how much wiring I need in the ceiling for puck lights and the maxx air fan before I insulate and close it off with cedar panelling. Also working on a passenger seat option up front and to soundproof the floor up there as well. I left a few ceiling panels free from the Siless as I will have to cut holes for the wood stove chimney, hot water heater exhaust pipe, shower fan and a possible shower area roof raise.
 

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looks great!
good move on doing the mechanical stuff first.
you dont want any surprises mechanically/money after spending all the time on the inside?
keep it moving during your conversion and dont let it sit too long.
it keeps everything in good working condition.
also you want stuff to break down now while local rather than out of town on a long vacation LOL
every week or two i would drive mine into town to home depot for conversion supplies.
by the time i finished my build i had gotton all the bugs out.
my water pump was the first thing that happened ETC.
ive got over 10k miles and i think 57 campsites on it now with no issues.
" knock on wood " LOL
if ya have two batteries get a little 3 amp battery tender from harbor freight or Walmart.
only like $15 or 20 bucks.
again your ride looks very clean!
keep up the good work.
enjoy the build.
:marshmallow:
 
looks great!
good move on doing the mechanical stuff first.
you dont want any surprises mechanically/money after spending all the time on the inside?
keep it moving during your conversion and dont let it sit too long.
it keeps everything in good working condition.
also you want stuff to break down now while local rather than out of town on a long vacation LOL
every week or two i would drive mine into town to home depot for conversion supplies.
by the time i finished my build i had gotton all the bugs out.
my water pump was the first thing that happened ETC.
ive got over 10k miles and i think 57 campsites on it now with no issues.
" knock on wood " LOL
if ya have two batteries get a little 3 amp battery tender from harbor freight or Walmart.
only like $15 or 20 bucks.
again your ride looks very clean!
keep up the good work.
enjoy the build.
:marshmallow:

Thanks for the comments and suggestions! Appreciate it. :Thanx:
 
Little update...

Finished curing all my T&G cedar planks using osmo polyx, started to insulate with the wool and put my furring strips on which will allow me with 4" of wool on the walls.

Lot's of people struggle with the wool vertically and you have to get creative but I found a pretty easy way to secure the wool using double sided outdoor carpet tape and then using reinforced duck tape on the other side for extra hold and it works pretty well!

Looking forward to closing up the lower walls so I can start framing my bathroom area and making cabinets and my bed as I feel. Still lots to do up on the ceiling area.
 

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Finished the furring strips and insulating the lower walls with 4" of wool. Hoping to get plywood on soon! 32 gallon wheel well water tank just arrived. Things are moving along... :dance:
 

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i dig those big windows!
most people pull them out for double pane or block them.
even if i had a shower i wouldnt block them.
i would have glass walls & doors LOL
we love waking up with the 360 degree view!
:marshmallow:
 
i dig those big windows!
most people pull them out for double pane or block them.
even if i had a shower i wouldnt block them.
i would have glass walls & doors LOL
we love waking up with the 360 degree view!
:marshmallow:

Yes a big part of buying a shuttle bus for me was for these amazing panoramic windows. I understand why people block them out for insulation but unless you're planning on living in extreme cold it makes no sense to me. I rather deal with insulated curtains, pumping more heat into the bus, etc. than cover them but this also isn't an extreme cold winter bus. I also don't enjoy dark spaces and need my space to feel open and bright when I can't be outside! :hide:
 
Hey everyone. Little update. Busy push now through the warm summer.

Lower walls are in. Wool is up. Electrical is done for ceiling (lighting, maxx air fan, speakers). Rear above doors was a pain and I couldn't get the thin wood I bought to flex enough so I used leftover carpet from my house and it actually fits perfect and looks great (future pic to come). Picked up a passenger seat with shoulder seatbelt intergrated as that will be a big project.

Got the first strip of cedar panelling on today after sorting out a rough idea of the pattern! Looking forward to having the walls and roof done soon so I can build the inside.

Thanks for following along. Love to hear any comments! :Thanx:
 

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Well... the ceiling and walls are all up! It feels like a nice place to be. Very happy with how my ceiling and rear carpeted walls turned out!
 

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