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Still to this day, after removing seats, building grey water tank mounts, and sweltering through 45 degree days, our Toyota Coaster bus conversion insulation remains one of the most annoying and hated jobs we have done!
The Insulation –
The insulation we chose for the bus was Earthwool with an R value of 2.5. It is very similar to the insulation we decided on for the walls. The only difference is it has a slightly higher R value. It is the same thickness of 90mm and was a very similar cost.
One of our subscribers on our Youtube channel suggested we could use a polyester insulation, easier to use and not as many consequences as the glasswool. This is something we looked into, but decided for cost, it was a better option for us to use the Earthwool and make sure we were adequately prepared.
The Process –
Learning our lessons from the wall insulation, today I came prepared. Full long sleeves, pants, mask and glasses were a must. Well I almost came fully prepared, I forgot gloves. When using your hands, gloves are extremely helpful to keep the insulation out of your skin.
Installing the insulation really is a simple job, just a little bit time consuming. I found it easiest to use scissors this time rather than tearing like the wall insulation. Whilst it was more time consuming, it was much neater and there was less waste.
I cut piece by piece, measuring with my hands as I was going. The insulation on the curved edges of the roof did not require any glue to hold in place as they fit snuggly into the metal edges.
For the insulation on the middle, flat part of the roof, I used a small amount of liquid nails and held it in place for a moment just to set the adhesive a little before letting go.
Now, do not do what I did. I tried to put the liquid nails directly onto the roof… and it came back down all over me. Of course, if I had thought about it, this wouldn’t have happened. But it did. It is definitely best to put the liquid nails directly onto the insulation, then place it on the roof.
When all the larger pieces were done, I went back and used offcuts to fill any of the smaller gaps.
It was as simple as that.
The result –
Pain!
Even though I was careful and had protective clothing, I did not wear my glasses all the time. I also at one point removed my mask and wiped my face with my hand. Mistake! A word of caution, wear glasses and do not wipe your face unless you have cleaned your hands. The result was glasswool all through my face and eyes. Itchy and sore for days!
Our Toyota Coaster bus conversion insulation however, looked great. The roof insulation is finally done, and that leaves us one step closer to completion!
Claire,
Great you are back on line – you guys are starring in Pinerest at present!! Trust your illness is controlled. I too have had my difficulties, my wife’s twin passed away when his life support was withdrawn on May 8th after an illness going back to his Heart Attack before Christmas. he has largely been in hospital (all but 2 weeks in after-care), and mainly ICU. Her totally dysfunctional family kept me busy in ministry!!
Anyway, have a paid job now, driving aged and infirm around for a local council, in Coasters!! We have 4 of them, plus a Renault Master to go to City Hospitals, and they recently replaced a Coaster with a Hi-Ace and both are disasters.
Anyway, back to the conversion, I thought while it was stripped, I would get some mechanical checks – first an alignment, as I noted the bus pulled a bit left. Well – the ball joints need replacing, especially the lower LHS. The mechanic suggested I pick them up – about $50 each – well first site – uppers for $70, lowers $890 – I fainted. Have got them now, but cost $1,200 for the set from Coaster Parts in Sydney. David is great, and reasonable if you need any parts. The lowers were also like hens teeth to find – everyone had the uppers.
Question – Why did you buy such a huge and expensive battery – I know little about electrical needs but that battery looks as if it could power a jet!! Also, it was suggested I put in my wiring before insulation and use conduit so that future wiring could be added, but Earthwool was recommended. Managed to acquire a second hand suburban 23 litre water heater for $250, against $800 through a manufacturer – the element did not work when installed into a new unit, so suburban supplied him a whole new unit. He has 2 others that need a few parts (one an anode, the other also an element), if you are interested. The anode and element are about $70.
Anyway, we continue on – all the best to you and Shane
Gavan Murphy
Hi Gavan,
Nice to hear from you again! It sounds like things have been quite busy for you with the new job. It sounds like you are enjoying it though and getting a chance to drive other vehicles not just Coasters.
Im sorry to hear about the passing of your wife’s twin. It sounds like a hard time and we hope both you, your wife and family are doing okay.
We purchased a big battery to try and cover everything we will have in the bus. We are hoping to eventually get air con as well so we calculated for this too. It definitely was a big cost to layout but we got it on a good sale at the Sydney caravan camping show.
We purchased a Suburban hot water system too. Thats a good price for a second hand one, they are expensive new. I believe ours was around $670 at the camping show. I am excited to see how it goes so you will have to let us know how yours is.
All the best to you too Gavan, keep us updated on your conversion!
Claire