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Toyota Coaster Motorhome Conversion – RV Shower Cubicle and Dometic Toilet Install

May 29, 2019 by Claire Edwards 3 Comments

toyota coaster motorhome bus conversion - installing rv shower and rv dometic toilet

A lot of people have been asking us if we installed a shower and toilet in our Toyota Coaster motorhome, so we thought it best to not leave this post any longer. The answer is yes!  

Having a shower and/or toilet in your RV is a preference which you need to decide is worth it. It is not something that is a necessity. Having been on the road for a couple of months now, we have found it is quite easy to come across public toilets and even public showers. A lot of caravan parks, rest stops and petrol stations have toilets, and some just ask a small fee to use them.  There is no need to stay somewhere just to use the amenities.  

So we decided to weigh up the pros and cons for having a shower and toilet in our RV to see if it was worth for us. Our list looked a little like this –  

Pros  Cons 
Not needing to use public restrooms  (YES!) Space consuming 
Convenience  Water usage 
Save money not paying for amenities  Leaks! 
Privacy  Smell (Yes, there is smell)
Self sufficient  Finding dump points 
Can go to more remote locations  

After looking at our list, we quite quickly opted for an RV shower and toilet in our Toyota Coaster bus plan. As much as we liked the look of the open plan motorhomes, we liked the convenience of having our own shower and toilet more.  

So what did we decide to do? 

You may remember from one of our first posts, we discussed that we wanted our bus to look like a home. Our RV shower was the hardest thing to do while trying to keep this in mind. 

One option we considered was building our own bathroom cubicle. We found it so difficult to find a shower base to fit in our desired spot in the bus; the dimensions were either too wide, too long, or it was just too expensive.  

Another thought we had was to customise the entire shower, including the base from waterproof material. We couldn’t work out what to make the base and walls from, and had no idea where to start. So this option was a no go.  

We ended up deciding on a pre-fabricated RV shower toilet combo. It isn’t what we wanted, but it would fit in the space we had, and the one we chose was already made to fit our curved walls.  

The shower toilet combo was purchased from Custom Coaster Conversions. It is no longer available for sale through Custom Coaster Conversions, however, you can purchase it at DIY RV Solutions. They do different moulds for different vehicles.  

It is a fiberglass shell which comes in 2 pieces to make it putting it in the bus and together easier. The dimensions are 1820mm high, 1000mm wide and 700mm deep (all at the biggest point). There is an optional shower door frame available which we purchased to go with it. It does not include the glass of the door (for safety/shipping reasons), and you need to organise that yourself. Ill discuss below how we decided to do that.  

The Toilet

There are so many different RV toilets available and we had no idea where to start. So as we did with everything, we researched. Here are the few most common RV toilets and a little breakdown of how each works. I wish I had found something like this!  

Roaming on rubber rv dometic cassette toilet - toyota coaster motorhome conversion

Cassette Toilet –  

A cassette toilet is a more permanent option in your RV. It is secured in place, and has a waste holding tank underneath.  

Once you flush the toilet, the waste goes down into the cassette and is stored until emptied.  

Most cassettes are accessible from the outside of your motorhome via a small door.  

The idea is to remove the cassette tank, and empty when needed into a dump point (a specific spot for dumping motor home waste – we have found these to be quite common everywhere in Australia, most RV friendly towns have one available).  

The good –  

Easy to find dump spots – readily available in most RV friendly towns.

Convenience – No need to find a public toilet, or a nice spot on the ground!  

Space saving – some cassette toilets come with a swivel seat which means it can be turned in any direction. This is handy in smaller spaces like ours.  

The bad –  

The smell. Yes, it can smell. 

We use specific toilet chemicals which help to break down the waste, and basically turn it into slush. This is what comes out of your cassette and into the dump point.  

Some dump points are definitely more cleaner than others, and we have found most to be perfectly fine and have had no issues.  There are the occasional few that do not have a hose available to rinse after you have dumped your waste; these tend to be the ones that are not quite as nice as the rest!

The smell is mainly when you open the toilet (there is a small hole which is only opened as you are about to go), and you can smell it from underneath.  

We have found regularly cleaning the toilet, rinsing it at each dump station, using the chemicals, and a few drops of eucalyptus oil every now and then helps with the smell.

Some examples of Cassette toilets –

  • Dometic CTS 4110
  • Thetford 263 China Bowl
  • Thetford C402C
  • Dometic Saneo

Portable Toilet –  

A portable RV toilet is essentially the same as a cassette toilet, however the waste holding tank is attached to the toilet itself, and the whole thing can be moved around as a unit. This is a good idea if you are not wanting a permanent plumbed in toilet, or do not have enough space for a bathroom but want the convenience of a toilet just in case.  

The good –  

Easy to find dump spots – readily available in most RV friendly towns.

Convenience – No need to find a public toilet, or a nice spot on the ground!  

Space saving – if you cannot have a permanent bathroom, at least you can still carry a toilet around with you.  

Typically a lot cheaper than a cassette toilet, so better for those watching their budgets!  

The bad –  

Generally a smaller waste saving tank, so it needs to be emptied more often.  

Not a permanent feature, so needs to be carried around with you.  

The smell! Always the smell haha!  

Some examples of portable toilets are –

  • Camec Portable Toilet – 20L (10L also available)
  • Thetford Porta Potti 365
  • Dometic Sanipottie 976

Composting Toilet –  

Have you ever chucked all of your vegetable and kitchen scraps somewhere and just left it to breakdown?  

That is essentially what a composting toilet is.  

It works by separating the liquids from the solids, and an additive such as peat moss, or sawdust helps to break it down.  

After you have used it, it can then be emptied anywhere you would normal compost. It is definitely recommended not to empty the compost around any edible plants, herbs, vegetables, fruits, seeds etc.  

The liquid can be disposed of at a dump spot, or even in a normal toilet as it has no chemicals in it.  

The good –  

It is the most environmentally friendly option. It is a dry toilet and doesn’t require water to use. If needed a quick spray of water from a bottle should do the trick.  

Easy to find dump spots. 

Convenient!

The bad –  

Typically the most expensive.

If you need to use toilet paper, it takes much longer to break down than the waste does, so you will be able to see this and would probably need to dispose of at dump stations. Alternatively, you can put your used toilet paper in a bin instead of the toilet.  

There is also RV specific toilet paper available. It is generally a lot thinner than regular toilet paper which helps it to breakdown quicker. Downside to this is the cost.

As it separates solids from liquids, it is not great for anyone who may be sick; sometimes there is an in-between!  

There are not a lot of composting toilets around, however a good example is the Natures Head Composting Toilet.

So what did we decide?

After looking at all of these options, both Shane and I were tossing up between a cassette toilet, and a composting toilet. We wanted a permanent toilet and both of these fit what we were looking for. After watching a clip on YouTube describing the composting toilet, we opted against it. The idea of being sick, or even for a girl during that time of the month and not being able to use the toilet turned us off a little. Not to mention it was more expensive! Because of this, we decided on a Dometic CTS 4110 .

The RV Shower Cubicle Installation

Step 1 – Waterproofing  

Before we installed it completely, we waterproofed the area underneath and around where it will sit using Crommelin Aqua Block – waterproof primer, and undercoat.

It is an easy task as it requires no thinning or modification. We used a brush and roller and just painted it everywhere we needed to.  

Like a lot of things, this is not a necessity but an option we decided was worth it to protect the wood underneath from water damage in case of a leak. And aren’t we glad we did! We have had a few leaks since and even though we know it could have done some damage to the wood, this water proofing was a little piece of mind.  

Step 2 – Measuring and cutting the toilet hole in the shower cubicle, and the wall of your bus 

Once the waterproofing was dry, we placed just the bottom half of our shower cubicle into position.  

This allowed us to sit our Dometic CTS 4110 toilet into place. By doing this, we could mark up where we need to cut the fiberglass shower wall so we can access our toilet cassette from the outside of the bus.  

The Dometic instructions were a little difficult to follow. After a bit of reading and re-reading, we ended up working out how to measure it up. It is different for each individual toilet they sell, so check out this guide which has all the measurements.  

Toyota Coaster bus conversion - measuring up the wall of our rv shower to install the dometic toilet

We measured the access hole for the cassette, drew it up, and drilled a hole into each corner. This gave us a starting point to then cut the fiberglass using a jigsaw with a fiberglass saw piece.  

toyota coaster motorhome conversion - cutting the rv shower cubicle for the rv cassette toilet

Hopefully, unlike us, you have already cut your hole in the bus wall and it is ready for your cassette toilet (if this is what you decided on). Or, are ready to do it now, prior to installing your shower.  

Using the measurements from the instructions for your toilet, cut the metal of your bus wall in the same position as your fiberglass hole. It can be hard to line up. We pre-drilled 4 pilot holes, 1 in each corner which gave us a starting point. Then on the outside of the bus, we used a permanent marker to draw up the size and check the measurements were accurate before preceding to grind the hole out.

toyota coaster motorhome bus conversion - cutting the hole for the rv cassette toilet

It is very important not to cut through any of the structural metal in your bus wall. Please check beforehand with your engineer so you know where you are cutting is safe.  

Step 3 – Cutting the holes for the drains  

Now that the holes are cut in the walls, it is time to cut the holes for our drains.  

The RV shower cubicle we purchased came with 4 specific spots for drains. When we initially were making the purchase, it was recommended to buy four drains and have one in each corner. That way, no matter what angle you are on, your shower will drain.  

What a great idea!  

toyota coaster motorhome conversion - cutting the drain holes in our rv shower

Using a hole saw, the same size as our drains, we cut out the 4 holes and preceded to put the bottom half of the shower cubicle back into place.  

Now that the drain holes were cut into the fibreglass, we traced around each drain hole onto the floor underneath for the plumbing to go in.  We then removed the shower cubicle again to cut these 4 holes through the sub floor of the bus as well.  

This was a mistake.  

After cutting the holes into the floor for the plumbing, we realised quite quickly that there was some structural metal underneath the bus that we could not cut through and could not get the drain hoses around. Two of the four drain holes would work, the others would not.  

This is definitely something to check prior to cutting!

Time to get some fibreglass and resin and fix the two holes in our shower cubicle floor we could no longer use.  

Step 4 – Attaching the two halves of your RV shower cubicle together  

Now we could finally sit the two halves in position together and attach them.  

The two halves are easy to attach together.  

We started by using Selleys wet area silicone between each of the halves and sandwiching them together. 

toyota coaster motorhome conversion - rv shower toilet combo being siliconed together

Then, on the outside of the shower cubicle, there is a small fiberglass lip. We used stainless steel screws to attach each half together on this lip, so they are not seen inside the shower. The reason we used stainless steel screws is to avoid any of them rusting from the water (if it leaks) in the future. Covering all bases! 

toyota coaster motorhome conversion - rv shower toilet combo

HOWEVER, and it is a big HOWEVER, we have since learnt that the silicone we initially use is not great for fiberglass.

We have had a lot of issues with leaks. After seeking some expert advice from Bunnings, we have now used Selley’s Marine Flex Adhesive Sealant. This is specifically meant for fiberglass and wet areas. So far so good, so we recommend this one over any others (and we tried 4 different types!).  

Your RV shower cubicle is now together and in place.  

If you want to, this is when you can install a roof hatch into your shower. It is not a necessity. We decided to have one, and if you want to know about our install, watch our video below 🙂

RV Cassette Toilet Install  

As we discussed early, we chose the Dometic CTS 4110 toilet. Lucky for us, this was also the one recommended to go with the shower/toilet cubicle we decided on.  

Step 1 –  The lip

The Dometic toilet we purchased for our Toyota Coaster motor home comes with a little piece of plastic which is used as a lip to help attach the toilet to the wall of your shower cubicle. Using the measurements provided, we pre drilled pilot holes and screwed it into place.  

toyota coaster motorhome bus conversion - installing rv toilet, dometic cassette toilet
Step 2 –  Sitting the toilet in place  

Now that the lip is in place, you lift the toilet up, and lower it back down onto the lip where it catches, and clicks into position. This can be a little tricky and may take a few attempts. You can feel if it works or not because it will no longer pull away from the wall easily.

toyota coaster motorhome bus conversion - installing rv toilet, dometic cassette toilet

With this shower cubicle, the RV toilet sits perfectly on a raised part of the shower floor. It has a rubber edge which goes all around the joint between the toilet and the fibreglass wall. behind it which is supposed to prevent water getting in behind it.  

We noticed straight away that it did not sit flush.  

toyota coaster motorhome bus conversion - installing rv toilet, dometic cassette toilet

After consulting with the supplier this issue, he advised us what to do to fix it (he does this with all of his installs too, so it is good to know!).  

To fix, we purchased 2 really long screws (8G X 140mm length) and screwed one on each of the 2 corners of the top of the toilet. These screws went through the toilet, and into the fiberglass shower wall behind. As we had discussed this, we knew there was nothing behind this bit of the toilet and it would be safe to do so. In doing this, it pulled the toilet nice and close to the shower cubicle wall which we were happier with; it means less chance of leaks!  

toyota coaster motorhome bus conversion - installing rv toilet, dometic cassette toilet
toyota coaster motorhome bus conversion - installing rv toilet, dometic cassette toilet
Step 3 – Attaching to the ground  

Now that your toilet is in place, it is time to secure it to the ground.  

From the outside of your bus, you can now remove the cassette that comes with your toilet. Check the instructions to see how to remove it if you are not sure. Ours has a little plastic lip which we push down, this then releases the cassette and it slides out. It can be a bit tough and can take a little to get used to.  

Once it is removed, underneath there are 6 places to screw through the bottom of the toilet and into the base of your shower cubicle to secure it in place.  

toyota coaster motorhome bus conversion - installing rv toilet, dometic cassette toilet

Using the screws provided, screw them in.  

Our Dometic toilet came with cover plates to cover these up. They simply sat into position and if you push down on them firmly, they click into place into plastic holes provided to secure them.  

If you ever need to remove these, we have found the easiest way is to use a flat head screwdriver. We just put this in underneath them and lever them just a little. It gives it enough force to remove them without damaging the cover plates.  

Your RV toilet is now secured into position!  

toyota coaster motorhome bus conversion - installing rv toilet, dometic cassette toilet

The Issues!

Once we began our journey and started using our shower and toilet, we quickly realised the leaks.  

The water was getting in and around the underneath of the toilet via the sides where the rubber was. The water even got in under the toilet seat and down into the bottom of the cassette!  

This is when we starting researching and thanks to one of followers, found out that this toilet is not meant for wet areas. In saying that, Dometic appear to no longer supply one made for wet areas, and this was the toilet recommended with our shower cubicle. So we figured it must work somehow.  

It was time to fix it – silicone.  

We used silicone for the entire edge around the rubber on the toilet, as well as around the base.  

Underneath where the cassette is accessed from the outside of the bus, we used silicone to get any holes we could see inside the shower cubicle.  

We pretty much sealed every single possible spot where water may or may not get in to the underside of the toilet and shower cubicle.  

If we are on an angle, or having drainage issues (which, there have been a few!), if the water level rises to the level of the toilet, we find it still makes its way underneath the toilet at the back and down under the floor. I guess it is about being aware what causes the issues to make sure that doesn’t occur again. This problem forced us to re-look at our drainage system.  

With the toilet seat, we ended up buying a shower cap to keep on it during showers. Such a cheap, and easy way to fix the leak issue! 

Now that the physical toilet and shower is in, it is time for tapware, plumbing and wiring up our RV toilet. Keep an eye out for our next post which will go through this.  

toyota coaster motorhome bus conversion - installing rv toilet

The Walls and RV Shower Door Installation   

Step 1 – Cardboard mould  

To get the correct curve for our walls, we used a piece of cardboard to make a cut out we could copy.   

We simply held the carboard up against the wall, and cut each bit piece by piece and adjusted as we went. It took a little while to get the correct shape, but it saved a lot of incorrect cuts later on.  

You can measure along the way if you like, however I found it easier just physically looking at it and cut accordingly.  

Step 2 – Cutting the walls  

For the walls, we used 16mm white melamine panel. This is a water resistant panel which is good for wet areas. With this, we strongly recommended water proofing and sealing all edges before installing them as walls. While the white side of the melamine is water resistant, the inside is most definitely not. As we have had leaks, the water has come into the walls from the underside, and we wish we had known, or thought about sealing them before putting them in place.  

To cut the walls, we used clamps to hold our cardboard cut-out against our melamine panel and trace around the outside. Something we didn’t realise at the time was how to get a nice clean cut on melamine. We were trying to use a jigsaw blade that had nice small teeth, however there is one other HUGE tip – use masking tape.  

Once you have drawn around the cardboard cut-out and put this aside, use masking tape on both sides of the melamine. Put it over the top of your outline, exactly where you will be cutting. You can still see the outline through the masking tape so if you need to, you can redraw it on.  

The reason you should do this, is it keeps all the small edges from flaking off while using the jigsaw. The jigsaw just rips through the wood and this helps to keep it together, and overall you will have a much neater cut.  

Wish we had known!  

Now time to cut it using a jigsaw. Ensure you have all of the necessary safety precautions and PPE. Clamp your wood in place to avoid movement, and cut around your outline.  

For the front of the shower cubicle, our piece of 16mm melamine was the width of our shower, plus 16mm on each side to allow it to overhang the side walls.  

We cut out a section for the shower screen to go in place. Depending on what you do for a shower screen, your instructions should tell you the dimensions required.  

The original instructions we received with our shower screen wanted this cut out section to be quite large, however it looked too big and we decided to go smaller just in case and trim more if necessary. I am glad we decided on this as the space wasn’t needed… however it did make it a little bit harder to get in place.

Step 3 – Checking and adjusting  

Once we cut our first wall, we tested and found there were a few spots to trim. Once happy, we used this first piece of wood as the outline for the rest, rather than our cardboard cut-out. Getting it close can take some time, and some patience, but it is worth it!  

Time to repeat for each wall – double checking along the way they all have the same shape prior to cutting.  

Step 4 – Attaching the walls  

We used a very simple method to attach our walls – brackets.  

Small L shaped brackets; these were only used on the inside of the wall where they would not be seen from the outside. Where possible, we attached each wall (in our entire bus) at the top, middle and bottom using 16mm wood screws into the melamine, and 30mm screws into our roof and walls.  

If we were unable to attach the wall using a bracket, the other method we used was attaching it to others things.  

For example, as we were unable to get a bracket on the inside wall of our shower cubicle at the back, we joined this wall to the front wall using angled screws down the side. After this, we used gap filler silicone to connect the top to the roof, as well as fill the gaps.  

toyota coaster motorhome bus conversion - installing rv shower walls

From the inside of the shower cubicle, we put two small screws on each side into the fiberglass. These went through to the melamine wall behind and attached the side walls to the cubicle. This stopped the middle of the shower cubicle bowing in.

toyota coaster motorhome bus conversion - installing rv shower walls
Step 5 – Door frame and screen  

This is the one page instructions we received with our shower screen.  

It is a blown out version of the shower screen and quite difficult to follow, and even more difficult to explain.  

If you have any questions, send them through to us and we will try and explain a bit better haha!  

Check out the video below of our shower screen. It gives you a few tips on what we decided to do instead of glass for the door, as well as some adjustments on the edging.  

Step 6 – Edging  

The final step to our RV shower/toilet cubicle was to edge. From Bunnings, we were able to purchase some timber edging.  They have a wide range available, and depending what suits you is what you decide on. We simply glued them onto the edges of our melamine and used the nail gun to secure into place while the glue set.  

So that is our RV shower toilet combo and how we went about deciding on what we did, and making it come to life.  

After being on the road for a couple of months now, we are definitely happy with our decision to install a RV shower and toilet. There have been so many times we have used it and we wouldn’t have it any other way!  

Check out the video below if you haven’t already, which shows us installing and building it.  

The next post up will be the plumbing, tap-ware and electrical so keep an eye  out for that.  

RV Shower and Dometic Toilet Install
RV Shower Door Installation
Claire signature

Filed Under: Conversion How-To, Toyota Coaster Bus Conversion Tagged With: bus conversion, bus life, bus shower, bus toilet, cassette toilet, chemical toilet, composting toilet, dometic toilet, portable toilet, rv shower, rv shower toilet combo, rv toilet, tiny home, toyota coaster conversion, toyota coaster home, toyota coaster motorhome

Toyota Coaster Motorhome Conversion – Building Your School Bus Lounge

November 7, 2018 by Claire Edwards 2 Comments

Toyota Coaster bus conversion - lounge framing

Everything needs to have 2 uses. That has been our thought process along this entire journey. There are so many options for motor home or bus lounges, which meant there was a lot of inspiration when designing our lounge. Our school bus lounge has not 1, not 2, but 3 uses!

Building a lounge is not something you have to do. There are a lot of pre-fabricated options available and a lot of places will be able to custom make one for you. We have seen a fair few people who use these and have no issues.

As with everything we have done so far, we decided to build our lounge for a few reasons; cost, space, storage and design. In our school bus floor plan, we explain that our lounge was very important to us and we knew we could get exactly what we wanted if we built it ourselves.

Toyota Coaster bus conversion - lounge framing DIY for beginners

The design for our school bus lounge –  

The first step for the lounge framing is to work out what you want from it.

The most obvious function is a seating area. We want it big enough to comfortably sit both of us, and an extra 1-2 people if we have visitors. It also has to be big enough that we would be comfortable, and could stretch out when watching a movie. We then decided to add an ottoman which will provide extra foot space, and also double as storage and a seat.

Toyota Coaster school bus conversion - building your school bus lounge

Storage is the next most important thing. With everything you build in your school bus conversion, storage has to be a consideration, and under the lounge is a perfect area . We had planned where our appliances were going so knew that the height and width of our lounge had to meet the size of our Suburban hot water system which we had decided to place underneath. There is then more room left over for other items that need storing, as well as the extra in the ottoman. 

suburban hot water system - toyota coaster school bus conversion - school bus lounge framing

Most builds we found either choose seat and storage, or seat and sleeping area. We wanted it all, so we designed our lounge so that it could perform all 3 functions! Our original plan was to have it extend so that we could turn it into a doubled bed. We didn’t have enough space to make a double bed, but we did manage to make it extend to the size of a single bed which is sufficient. It also means that while we are watching a movie or just relaxing, we can extend this and have a bigger space to relax for ourselves also.

Toyota Coaster school bus conversion - building your school bus lounge

How were we going to achieve this? The base (where we sit) would have interlocking panels that would separate and slide out to become the bed. It would then have hinges to lift the entire base up to access the hot water and storage underneath. We then decided to have the front lift so we have a partial foot recliner as well. It was such a complicated design but we managed to make our lounge frame work.

Confusing? Let us get into more detail.

Building our school bus lounge – The base frame  

First we used 35mm x 70mm timber, and built the initial base frame, which provides the structural support and attaches to the floor and wall. We used 50mm wood screws as well as wood glue to make the joins secure. We started with the floor pieces, then attached the uprights followed by the top pieces.

Toyota Coaster school bus conversion - building your school bus lounge

The Interlocking System 

The base frame was the easy part. Planning out the interlocking slide out system was the difficult part. Shane and I wanted it to be separated in half, so that they could pull apart and extend separately to make a corner lounge, and together to make a bed. This would also allow them to lift separately to access different areas of storage. These interlocking pieces were made using 19mm X 64mm dress pine.

Toyota Coaster bus conversion - lounge framing

Every second slat is referred to as ‘fixed slats’. These are attached to a row of dress pine, and fixed at the back with hinges. The front end of the slats are attached to another piece of dress pine on the inside of the lounge frame. As we want the slats to lift up to access storage, they had to attach to something that was not attached to the base frame. This is why we have added these additional pieces of dress pine.

Toyota Coaster bus conversion - lounge framing

The pieces that slide out are also attached to a piece of pine, on the outside of the frame. This piece keeps all the slats together as one, when being slid out. If you look at the picture below, two of the slats are made longer. When the lounge is pushed together, these longer pieces sit on the edge of the lounge and prevent the slide out pieces from falling down.

Toyota Coaster bus conversion - lounge framing

These longer pieces continued to get stuck on the edge of the frame when we pushed the lounge back together, which can be seen in the video. We ended up placing a washer underneath the longer pieces which lifted them slightly. We also sanded back the edge that they sit on, providing a rounded lip, rather than a corner. This has prevented them from getting caught and allows them to slide and sit in together without issues. 

Toyota Coaster bus conversion - lounge framing

After this, we added a smaller piece of wood cut to size which is fixed in between the two sliding halves. This provides a guide so that they slide out straight and prevents them getting stuck. 

Toyota Coaster bus conversion - lounge framing

The ‘Recliner’

The front of our lounge has been made using 12mm ply. It provides the ground support when the lounge is extended for the bed. As our lounge ended up being slightly shorter than we wanted, we joined this 12mm ply on with hinges. When lifted up, a small 20cm piece of dress pine (also attached with hinges), falls down from underneath, propping the front 12mm piece of ply up on a slight angle. This gives us our ‘recliner’. 

Toyota Coaster bus conversion - lounge framing

Our back rests are made with 35mm X 70mm wood, cut into the base frame. We then attached 12mm ply to the front of them, which provides the back rest.

We will use Dunlop foam for all of the lounge cushioning. This cushioning we will get custom cut to size and then we will make covers for the cushions ourselves.

After building our kitchen frame, the lounge was a huge step in our Toyota Coaster bus framing and we are so amazed we were able to pull it off.

The more we build ourselves and the more experienced we get, the better things worked. As hard as it has been to do on our own it has been worth it.

If you haven’t already, watch our video below of our build and let us know what you think.

Filed Under: Conversion How-To, Toyota Coaster Bus Conversion Tagged With: bus conversion, bus life, motorhome lounge, school bus conversion, school bus lounge, toyota coaster conversion, toyota coaster home, toyota coaster motorhome

Toyota Coaster Motorhome conversion – Building Your School Bus Kitchen

October 15, 2018 by Claire Edwards 2 Comments

Building and framing your school bus kitchen can be a difficult job if you don’t know what you are doing (like us!). There are so many different types of wood, screws, adhesives, joins, cuts and more. We were in way over our heads when we decided to start our Toyota Coaster bus kitchen and thought we could get it all done in 2 days. Ha!

Building the frame for our kitchen has been something we have been looking forward to for such a long time! We had ‘planned’ to spend 2 full days at the bus; framing the kitchen, lounge, bathroom and bedroom, and were hopefully going to smash it out. Everything was prepped. The materials were bought. The car was loaded and we had been to Bunnings for the last time. We were set, and it was time to go.Framing your bus - Claire on the trolley at Bunnings getting wood for their Toyota Coaster Bus kitchen conversion

So where do you start? 

After chatting to a builder friend about our bus conversion floor plan, it was decided to start with the most functional place first; the kitchen. Our thoughts were, once the kitchen was finished, we could then work on the lounge room and bathroom, leaving the bedroom until last. Getting the most practical and ultimately the hardest part done and out of the way first, would hopefully mean a much smoother fit out. Our bed will run across the back wall of our bus in front of the wheelchair access ramp and make it much more difficult to get things such as wood and appliances in and out of the bus, so leaving it until last seemed like the best option.

Why did we decide to build our bus kitchen ourselves and not get it built for us?

The way you decide to fit out your bus is all personal preference.

There are a lot of companies who offer the service of fitting out a bus for you. A lot of people also opt to use pre-fabricated or ready to go kitchens to save time and effort. Functionality, space, cost, electrical, plumbing – there are so many factors contributing to the bus layout and framing.

Shane and I chose to build our kitchen ourselves for a few reasons. Design; we are getting exactly what we want and where we want it. Money; motorhome and bus kitchens can be expensive. We saw this as a cheaper alternative to do it ourselves than to have someone build it for us. Materials; we had the option to buy a pre-fabricated kitchen from a kitchen place or even our local hardware shop Bunnings. However, we decided against this as we had read a lot of forums that had discussed the kitchens being too heavy and affecting their weight restrictions, and also not being structurally strong enough to withstand being in a motorhome.

Whatever you decide to do, it is definitely something to consider thinking about prior to starting. Trust us, it only gets harder and more complicated.

What’s in our bus kitchen?

We wanted a relatively open layout in our Toyota Coaster bus, with lots of storage, but also with everything required to live comfortably on the road. Our kitchen was to have a 175 litre fridge, a combined oven and stove, a sink, washing machine, and a microwave. It was also to have plenty of storage, overhanging cupboards, a backsplash, and external access to the batteries.

Sounds like we don’t have much at all to squeeze into a 2.4 metre space do we?

That’s when we instantly saw our bus kitchen was going to be tight, really tight. We had drawn countless diagrams, measured multiple times and were trying to work out the best possible way to squeeze it in. It was decided, we just couldn’t do it. Shane and I were trying to fit all the conventional items from a house sized kitchen and laundry into a caravan sized kitchen.

We came to the decision that the washing machine was to move. We would fit it elsewhere. This compromise would allow us to fit everything we needed to into the space we had. So now that was decided, it was time to get to it, and actually build it.

What tools and equipment do you need for building your bus kitchen?  

Shane and I have no experience with bus framing, or any sort of framing at all. We failed to seek a professional or someone who was more capable than us to help, so we decided to try our luck ourselves. With time restrictions and trouble organising schedules, we researched to come up with a plan, and a design for the frame.

We decided for the majority of the framing, we would use 19mm X 64mm pine wood for our main frame, and 35mm X 70mm wood for the things that were requiring a bit more structure.

The original plan was to use 35mm X 70mm timber for everything, however, after looking at our space, and working out measurements, we decided it was not a viable option and would take up too much room. Both of us have seen plenty of kitchen layouts using similar sized wood or no frame at all. The thinner pine framing would have to do. It was a bit more expensive than we originally wanted. It was decided for the space it would save us, it would be worth it. We were still going to use the larger 35mm X 70mm for our lounge and bed, as they will be carrying more weight.

Toyota Coaster Bus Conversion Framing - Bus Kitchen Wood

As with everything, the structure and what materials you use for your bus kitchen and framing is definitely a personal choice. Whether you decide to use the thinner pine, or the structural wood it is up to you. We have seen a lot of people who have done bus conversions! They have used metal for their framing, and some have just used the walls for their cupboards and had no framing at all. So whatever you decide, as long as it is structurally sound and meets any sort of regulations your state or territory may have, it is all a personal choice.

It was time to splurge a little! We purchased a nail gun to help with our bus framing. We got nails in various sizes, big enough to go through any of the wood we purchased to tack pieces together. The reason we decided to buy this was for convenience. It would be so much easier to tack the frame together with nails before screwing, to make sure it was right and to make it easier on ourselves.  The different sizes gave us variety, and easily accessible options when required. This would have to be one of the best purchases we have made to date! It is definitely something we recommend for anyone who is going to be doing a bus conversion themselves.

We also purchased timber screws, and metal screws. The timber screws were for the frame when attaching wood to wood, and the metal screws were to attach the 7mm plywood panel we got for the walls, to the bus. The metal screws were also for any structural support pieces of framing that needed to attach to the bus’s metal beams.

Toyota Coaster school bus conversion - building your bus kitchen

For each joint, we also used wood glue for added strength.

Shane tells me I like to go over the top with our bus build. I figure, that this is going to be our home, and I don’t want it falling apart on our first rocky road, or ditch that we fall into. I want our Toyota Coaster bus frame to be structurally sound.

Where do you start framing in your bus conversion? 

The walls and wheel arches; that’s where we started.

The amazing thing about Bunnings, is they cut wood to size for you.

We had measured our walls and wheel arches and knew the measurements we needed our pieces. We decided on plywood.

Plywood is a relatively inexpensive option for bus wall framing and if thin enough, it is easy to bend and manoeuvre along the curves of the wall.

Originally we were going to go thin for the walls – 3mm, however decided after looking at it, and knowing it may be damaged easily, we decided for us thicker would be better. We have read many forums and seen a lot of people who have used 3mm ply for their walls and they love it and it works. This is a personal choice, and there are a lot of considerations such as weight and structure that need to come into it.

Unfortunately, there is no happy medium between 3mm and 7mm unless you get marine ply. Marine ply is amazing as it is made to be used in waterproof areas such as boats etc. Amazing things generally come with a price. For each piece, it was $10 more expensive, and we were going to need a lot of it. 7mm ply for our bus walls was decided.

Toyota Coaster School Bus Conversion - building your bus kitchen

We had Bunnings cut each piece for the walls to 73cm high. We knew this would take us to our window level. The benefit of Bunnings cutting it was one, it made it fit in the car so much easier! Two, it saved us so much time and effort, and three, it was ready to go when we got to the bus. It was also free! An amazing service provided. It’s a great idea to check with your local hardware store of timber yard, wherever you purchase your wood to see if this service is provided.

So we returned to our Toyota Coaster bus, 7mm ply cut to 73cm high in tow, ready to go.

We purchased sheet metal screws at 20mm length, and self-drilling metal screws at 32mm for the walls. These would be long enough to go through the ply, and into the metal walls of the bus without penetrating through to the outside. If we knew then what we know now, we would not have purchased the sheet metal screws. We found they are not strong enough to penetrate the metal walls easily and we have not used them since. We would have saved a lot of money had we known that earlier.

Our Toyota Coaster bus has curved walls; this makes it difficult to create right angled joints which are attached to the metal structure of the bus. A plan was put in place. By marking where our cupboards were going to go to, we then measured the depth in two different places; the floor and the window sill, to the edge of our cupboards. The difference in these two depths showed us how big of a support piece we needed behind our cupboards so that there was no curve with our frame. It worked out to be 35mm – the exact width of the wood we had purchased. So, we screwed a 35mm X 70mm beam across the ply at the height where it would start to bow. While difficult to explain, it meant that our bus kitchen cabinet would have a structure behind it where the walls curve, rather than sitting on nothing. It would be supported.

Toyota Coaster bus conversion floor plan - wall installation and wall insulation

Now that our beam was attached to our ply, we attached our ply to our bus wall using the self drilling metal screws.

It took a little bit of effort and a bit of patience, but piece by piece the walls went into place. By pushing hard and flexing the plywood as we went, it matched the curve of the bus beautifully without cracking. If we had used thicker wood, it may not have had the flex to get the curve as well as the thinner wood. And if we had gone with the 3mm, it may not have had the strength to withstand the pressure required to screw it into the metal bus frame. So we were happy with our decision to use 7mm plywood for our bus walls.

Goodbye bus wall insulation!

The wheel arches protrude into our kitchen area a little. So we decided to build a box using 9mm ply to cover them. This is not a necessity, but we decided it would be easier to build around a box, than a curved wheel frame. It is not a structural piece, so we just used wood glue and the nail gun to tack them together.

The kitchen framing –  

Simpler is better.

Start by measuring everything. We measured all our appliances, measured the space we had, and made it as even and neat as possible. We drew a diagram, which had all our measurements on it so we could constantly refer back to it.

They say measure twice, cut once. And I am very glad we did because we got it wrong the first time!

Deciding not to over complicate things, we had hoped we would get it done nice and quickly.

Starting with wood glue on each piece, we used the nail gun and tacked each of the 19mmX64mm pieces together in the form of our kitchen.

Our screws we picked were 30mm X 8G.  8G is the thickness of the nail. And it was too thick! After we tacked each piece we also screwed the joints together. Unfortunately this was causing some of the ends to separate and split. Not good!

Toyota Coaster bus conversion floor plan - bus kitchen framing

Back to Bunnings we went. We thought maybe thinner screws would fix the issue. We purchased the same 30mm length, but in 6G thickness. It didn’t work. For us, we are extremely new to this and it began to get overwhelming. So we decided to try and pre-drill the holes prior to putting our screws in.

It worked! No more wood splitting. This is something we have continued to do throughout the rest of our framing since and is definitely a recommendation for anyone who is going to embark on a similar journey. Sometimes, we forget or get lazy and don’t pre drill. Almost every time we regret it as we have the same issues with the wood cracking and splitting. So take it from us – pre drilling works – do it!

The pieces came together, and our bus kitchen framing took its shape.

Toyota Coaster bus conversion- Shane and Claire bus kitchen framing

Once we were satisfied with the framing and had double checked our measurements, we decided to attach it to our bus floor and walls.

Butting it up against the 35mm X 70mm piece of wood we had used to tackle the curve of the bus wall, we manoeuvred it into place and used 40mm wood screws to attach it to the floor and the walls. This was just a very basic structure that still needed support however once screwed into place was already feeling solid.

Stepping back, we then took a good look for where we would start next. We found if you start with the most complicated bits first, it is easier to work out the errors if something was to go wrong. And we had so many issues! It sounds easy as I write it all down, but it’s not. We had problems with wood not aligning correctly, being the incorrect size, splitting, drill pieces breaking and more. It happens! This is why it took us so much longer than we initially planned.

Framing your bus kitchen. Claire and Shanes Toyota Coaster conversion bus frame.

The restrictions with installing an oven into a bus – 

So our next thing to tackle was where our oven would be placed. This was the main structural item that needed to be built into our kitchen framing and it was probably going to be the hardest.

We had purchased a Thetford dual fuel fan forced oven. There are a lot of restrictions with an oven inside a motor home. This is not something we had taken into account when we initially started the framing and our bus conversion plan and design. It needs to be certain distances from cupboards, walls, and anything else that could be a fire hazard. There needs to be a hole underneath where the gas can be tunneled so it can then go to an external vent outside. All these restrictions and regulations left us scratching our heads and coming up with new plans and workarounds.

Taking into account our bench top thickness, we start by measuring from the top down to where the bottom of our oven would be placed.

We then used our 19mm X 64mm wood to build a frame and place a piece of 7mm ply on top to provide a base support for our oven. After this, we built walls using 19mm thick wood to match our current framing. This stops any external droughts coming into the area where the oven will be located.

Cutting the bus kitchen bench – 

The next step was something we had greatly anticipated; the bench top.  It needed to be cut to size and then have the oven and sink holes measured and cut. We initially were going to have a wooden bench top; however decided due to the upkeep and maintenance of wood, we went with a laminate bench top instead. This also saved weight.

Measuring up the sink and oven was relatively simple; measure twice, cut once. So glad we did this! We just had to decide on their exact placement and take into account the overhang of the bench top at the front and rear. Once measured and drawn up we started with the sink hole. Pre-drilling a hole and then using a jigsaw allowed us to easily cut the hole required. The oven was even easier, still using the jigsaw slowly make the straight cuts.

Framing your bus - Toyota Coaster school bus conversion framing. Claire and Shane cutting their bus kitchen bench for their bus.

Once it was put into place and checked to make sure it fit, we used 40mm wood screws to attach our base to our bench. It was screwed from underneath so the screws are hidden.

This process of the oven frame and bench top took an entire day. There were issues with the oven not fitting and constantly needing to make adjustments. We also had a measurement issue where we forgot to take into account the overhang for the bench top. It was super frustrating but we are so happy with how it turned out!

Framing your school bus - Toyota Coaster school bus conversion -bus kitchen bench top frame

The next step in our bus kitchen frame will be to make our cupboards and install them. We are hoping as with everything that will be the easy part. We will also begin work on our lounge and anything else we can to finish our home!

Filed Under: Conversion How-To, Toyota Coaster Bus Conversion Tagged With: bus conversion, bus kitchen, bus life, motorhome kitchen, rv framing, rv kitchen, school bus conversion, school bus kitchen, tiny home, tiny home kitchen, toyota coaster conversion, toyota coaster home, toyota coaster motorhome

Toyota Coaster Motorhome Conversion – Roof Insulation Removal and Finishing Underlay

March 27, 2018 by Claire Edwards Leave a Comment

So after taking a break from our Toyota Coaster bus conversion and heading to Bali for a week, we are back now and it’s time to get stuck into it and finish building our home! Today’s goal was to finish sealing our bus floor so we could install our underlay, and remove the roof insulation.

We were both so excited when we arrived because we knew that the day earlier we received a pallet of goods we had ordered. And there it was; a shining cling wrap film of hope. It was beautiful. We opened it up to find our shower module, specifically built to fit a Toyota Coaster, our new toilet, water tanks, roof vents, hatches and more. Besides our fridge and washing machine, this was our first large purchase.

Toyota Coaster bus conversion - bus insulation and underlay

Once we had both gotten over the excitement of our new goodies, it was time to check out the bus and where we were up to.

Finishing The Sub-Floor –  

Toyota Coaster bus conversion - bus insulation and underlay

You might remember that from our last trip to the bus, we had replaced the back portion of our sub-floor and had glued it in place.

If you missed it, check out here.

Now it was time to screw the new sub-floor in to the chassis of our Toyota Coaster for extra support. Using a drill and multi purpose self drilling screws, Shane attempted to screw these into the into the chassis. The screws of course were unable to penetrate the metal, they were general purpose screws and not metal specific. It also would have been a benefit if we had an impact driver, rather than just a drill. Shane tried this with such grace that he ended up detaching the wood from the chassis which we had glued down last time. After some much needed advice from my brother, Shane and I decided against securing the wood with screws. We reapplied glue and left it to settle.

Silicone Sealing –  

Shane finishing the floor sealing - toyota coaster bus conversion

Finally we finished sealing the sub-floor!

After the decision was made to leave the new sub-floor without screwing it in, it was time to finish sealing it. We decided to leave Shane with this task, how hard could it be? I had managed to seal the rest of the floor, surely he could do the last little bit. Again… watching from the sidelines, my brother stepped in to give him some advice. After this, Shane managed to do a good job. All the cracks, gaps and holes in the floor were finally sealed.

Roof Insulation Removal –  

Shane and Claire removing the bus insulation in the roof - toyota coaster bus conversion

This part of the renovation we had not been looking forward to; removing the bus insulation in our Toyota Coaster motorhome. Removing this insulation was one of the first decisions we made regarding the bus. After researching online, we realised that the current bus insulation in the Toyota Coaster is highly combustible. We came across a video someone had posted on a Facebook forum, comparing the current bus insulation with a new Earthwool insulation. Considering we are turning it into our home, we decided to remove the current bus insulation and replace with something a bit more fire retardant and with better insulating properties. To read about which bus insulation we chose, read our post here.

Back to the removal of the insulation. For safety reasons, we used a face mask during this process as we do not know what the current insulation is made of and being a 17 year old bus, didn’t want to risk anything. The majority of the insulation just pulled off, however, we had issues removing parts where glue was applied. We used paint scrapers to try and remove the majority and I ended up settling on a chisel because of the sharper edge. We were unable to remove it all but we were satisfied with just removing the majority.

If we could go back, we would have worn gloves and full cover clothing. The glass fibers from the bus insulation get stuck in your skin and can be very harmful.

Removing bus insulation in the roof - Toyota Coaster school bus conversion

Finalising Underlay –  

It was now time to lay the remainder of the floor underlay. We were so excited to cover the last bit of our sub-floor. It feels like we have been working on the floor so long now and both Shane and I are so excited to be able to start on something new. You all know we love to start new jobs… and if you don’t, please refer to our two part ‘Day of Halves’ posts.

Part 1

Part 2

Shane and claire laying underlay in their Toyota Coaster school bus conversion - bus insulation

So we cut and measured the final foam underlay. We choose a thin, 3mm, underlay so that we did not reduce the ceiling height as much as possible. This underlay is made to be laid under floating floorboards. At this stage, that is what we were thinking of using, so thought it a good idea to lay down early and cover our sticky floor. We simply laid it down and used insulation tape to join the underlay together. This is a thermal tape we purchased with the intention of also using it throughout the rest of the bus.

And that was it. I walked away feeling as though we had not achieved as much as I had wanted. After re-reading what I have just written, I can now see it was a successful day. We got multiple jobs completed which allows us to start something new and exciting in our bus conversion.

It’s always a fun day at the bus – let us know your thoughts on our progress.

Filed Under: Conversion How-To, Toyota Coaster Bus Conversion Tagged With: bus conversion, bus insulation, bus life, camper insulation, caravan insulation, motorhome insulation, roof insulation, rv insulation, toyota coaster conversion, toyota coaster home, toyota coaster motorhome, wall insulation

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Childhood Sweethearts || Travel Bloggers || Coaster Bus Renovators || Australian Photography || Van Life || Entrepreneur || www.roamingonrubber.com 🐱

Last weekend (8/7) I got to marry my best friend i Last weekend (8/7) I got to marry my best friend in front of a small crowd of our nearest and dearest at a beautiful alpaca farm in Broke NSW.

This year has been a massive roller coaster for us. We’ve lost loved ones, our bus is still at the mechanic which isn’t looking to change soon, and our run-around car just recently died. But we have also just gotten married and got to surprise everyone with the announcement that we will soon be welcoming another member to the Roaming on Rubber family.

We keep reminding ourselves that these setbacks aren’t the end of the world and as long as we are together we know it’s going to be okay.

-Shane

The day wouldn’t have been as perfect as it was without our amazing vendors.
Would easily recommend any of them again, special shout outs to @chameleoneventhire , who went above and beyond to keep the night running smoothly, and @benjonescelebrancy who crafted the perfect story and ceremony for us.

Location: @starlinealpacasfarmstayresort 
Celebrant: @benjonescelebrancy 
Photographer: @weddingsxmemories 
Event staff: @chameleoneventhire 
Food: @woodfiredpizzacompany and @the_gelato_man 
HMUA: @cmphairartistry 
Suits: @mb__apparel 
Dress: @bellesandbeauxbridal 
Alterations: Just Perfect Alterations
Ties: @peggyandfinn
Some harsh realities of Bus life and our worst fea Some harsh realities of Bus life and our worst fears came to head on Friday.

We have been pretty quiet on social media the last few months while we waited and waited with bad news after bad news. Just as we were nearing the end and looking like we may be back on the road soon, we got the news that our bus’ engines block is cracked right through and that we have no repair options.

It’s a new engine or nothing.

So we aren’t sure what our plan is and if/when we will get back on the road as we can’t really afford that.

We are just trying to stay positive, and work out our next steps.

Thank you to people who have messaged asking where we have been, it means a lot.

For now we have started a short lease on a rental so not up to too much post worthy but hopefully we will be back on our feet in no time.
We’ve had a few setbacks so been a little quite We’ve had a few setbacks so been a little quite recently but we are almost finished! Cleaned for the valuation so thought we’d give you a look. Let us know what you think!
Not much work to go now! We just need to finish t Not much work to go now! 
We just need to finish the bathroom, build a kitchen overhead, add some trim and doors, and do a bunch of painting. Surely that won't take too long? 😂😂😂

#busconversion #vanconversion #buslifeaustralia #buslifeau #vanlifestyle #vanlifemovement #vanlifer #vanlifeideas #vanlifeaustralia #homeonwheels #homeiswhereyouparkit #thisisvanlifeing #vancrush #offgrid #busbuild #vanbuild
Sorry for the delay in posting! We have been so bu Sorry for the delay in posting! We have been so busy building the bus it has put us a little behind with our updates.
But our new desk is in! 
Made from the same Vic Ash wood as our kitchen bench, this beauty is long enough for us to both share the space 😊

#buslifeaustralia #busconversionaustralia #vanlife #vanlifeaustralia #busconversion #buslifeau #homeonwheels #homeiswhereyouparkit #thisvanlifeing #vancrush #busbuild
We loved our old wooden roof in the coaster so hav We loved our old wooden roof in the coaster so have just finished installing the same panneling in the Vario.

Plan is to paint it white this time rather then staining it.

Putting this in has really made us realise how much more space there is.

It's coming up great if we do say so 😁
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