Roaming on Rubber

Unplanned and Unstoppable

bus to motorhome

Our New Bus Conversion and Tips On How To Get It Right The First Time

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We’ve done it again! We have sold our much loved Toyota Coaster, and decided to do a new bus conversion on our Mercedes Vario. You may thinking why? Well after living in it full time for almost 18 months, there were a few things we decided really didn’t work for us. Rather than trying to fix them, we decided to sell up, and start again! Read below to see what kind of bus we bought and why, what we will be doing differently, and bus conversion tips to help you get it right the first time.

The New Bus

Our new bus is a 1997 Mercedes Vario. It is a 4.2 litre, 4 cyclinder turbo diesel automatic.

It is approximately 7.8 metres long, with an internal height of 1.9 metres and a width of 2.1 metres at the floor, and even wider at the windows.

So not only is it longer, but taller and wider than the Coaster. This will allow Shane to stand up freely, and for us to have a much wider hallway. We never imagined how much extra space that little bit of length and width would give us. Oh and its automatic – Shane can finally drive it! And maybe even one day get his licence 😉

roaming on rubber - bus conversion tips - mercedes vario

So why did we decide to sell our Toyota Coaster and get a Mercedes Vario?

Office space –

The first and foremost reason we decided to do a new bus conversion was because of the office space. Both Shane and I are constantly using our laptops for this blog, our YouTube series, and study. Shane has also continued to work remotely 3 days per week as an IT Technician. In the planning of our Toyota Coaster bus, the office space was an afterthought. We had a fold up dining table which Shane would use, but no space for an office chair. The solution was a boat chair mounted to our lounge for Shane, and I ended up doing everything whilst sitting on the lounge. This was not convenient, or comfortable! Not planning this was a poor decision, and the office space should have been at the forefront of our minds considering how much we require it.

We could have remodelled the Toyota Coaster to fit a better office space in however, after thinking long and hard we decided that to do that we would be compromising too much on our lounge and dining areas. We felt as though a slightly bigger bus with a better layout would be better.

In our new Mercedes Vario, a larger, more comfortable office space has been in the plans from the very beginning. We are going to ensure there is a large enough desk for both of us, as well as having comfortable office chairs. The plan is to find office chairs that can be used throughout the day, and stored underneath the desk when not in use. 

Thin hallway –

When we were building our Toyota Coaster, we were trying to think about the layout as much as possible. We tried to build it in a way that made sense – starting from the back; bedroom, closet, bathroom, kitchen, with living area at the front. What this meant though was the two largest things (the bathroom and fridge) were almost opposite each other.

This caused a very small entrance to the hallway and made it feel quite claustrophobic.

Not only did it feel very tight, but it meant that we had two very large walls right near the entrance of our home. This closed the entire bus off.

roaming on rubber - bus conversion tips - Toyota Coaster

The idea for the new bus is to have the larger things (fridge and bathroom) on the same side. Whilst this is not as appealing as having the fridge on the same side as the kitchen, we believe the benefits of space will overcome this.

We have also arranged for any internal walls to be as close to the rear of the bus as possible. By doing this, we hope the bus will feel a lot more open and not so claustrophobic!

In all honesty, these were the two main things that we wanted different that were enough for us to build a new bus. Even though these were the primary things, there were other things we have decided to change in the new bus. 

Things we want to do differently

Dinette –

In our Toyota Coaster, we had a small drop down table that was used as a dining table/office area. Whilst it was handy to use as a table, it was not in a convenient location that could be used to actually eat at. The plan for the new bus is to have a removable table top and leg that will be stored in the lounge. It can come out when necessary and be used along with the lounge to eat at. We will also have captains swivel chairs in this bus as the driver and passenger chairs. The same removable table top and leg will have a position in between the swivel chairs for a more formal dinette area.

Lounge –

Our previous lounge had all the bells and whistles; slide out to make a single bed, lift up for storage, and lift up foot rest. The problem was it had so much going on, that it was too much! It ended up being difficult to use, hard to access the storage, and we gave up on the foot rest idea. We had custom cut foam, and had covers made up to fit. It was very expensive, and after a long time sitting on it, it became uncomfortable.

roaming on rubber - bus conversion tips

The new bus will be much more simple. It will just be a lounge with storage. It will house our hot water system, cat litter, and our fold down table. We will have 2 small collapsible ottomans, so they can be put down and stored when not in use.

The lounge cushions will be thicker on the base, and we will have large softer cushions for the back.

Kitchen –

Kick panel. Omg we need a kick panel! In our Toyota Coaster, the idea of a kick panel seemed like wasted space. However, after opening the cupboards endlessly on our toes, we can definitely see the need for a kick panel! And now realise why it is called a ‘kick panel’…

Even though it takes up space, we have plans to have our air conditioner come up from under the bus into the kick panel area, at least then it is hidden from the inside. So still useable space!

All of our cupboards will have either drawers, or slide out storage; making everything much easier to access.

We have decided to buy a flatpack Kaboodle kitchen from Bunnings this time rather than build it ourselves. Whilst it is heavier, it will save us a lot of time, effort and surprisingly money to do it this way.

Our bus conversion tips; how do you get it right the first time?

Consider your bus size, plan and priorities –

Before even buying your bus, draw up some plans and work out how much space you will need, and what you want to have in your bus.

You might find that if you will be living in your bus full time, your needs may be different than if you are just using it for travel. For example, you may want a full toilet, shower and kitchen. Consider whether you will be staying in remote places and need to be off grid, or will primarily be staying in caravan parks. This will determine if you need a generator/solar, batteries and onboard water storage.

If you will be working in your bus, or like to do a lot of things online, do not underestimated your office space! Prioritise it. Comfortable seating and a good work area is a must.

What are your hobbies, or interests? Make sure you have the room to store things if you need to, or plan your design around them. Don’t leave anything to the last minute like we did.

We have a helpful planning guide here if you want to have a read in more detail 🙂

Photo of drawn up plan for our Toyota Coaster bus conversion. Roaming on rubber- things you should know before doing a bus conversion

Don’t overcomplicate things!

One of our biggest bus conversion tips is don’t overcomplicate things! It may sound simple, but when you have limited space you may find you are trying to squeeze as much in as possible. Sometimes this just makes it too hard, takes too long, costs too much and doesn’t always work out. The saying “keep it simple” really is relevant here.

We have spoken to other people who have done their own bus conversions, and most agree that generally when something is too complicated, it ends up not being used.

Learn tips from others –

If you have an idea, you can pretty much guarantee someone else out there has had it too! There are so many great forums, blogs and pages like this that have tonnes of bus conversion tips, information and ideas. And like us, not all of them have worked and we all learn from each other.

Don’t be afraid to message people directly and ask their opinion, ideas, or what they would have done differently. Most people love to share their knowledge in the hopes it will help someone.

Also, check out our in depth guide “Things you should know before starting a bus conversion“. We discuss budget, time to build, planning, buying a bus, licenses and more!

So now that we have sold our Toyota Coaster, we are well on our way to completing our Mercedes Vario. It has been a big change, but so far are glad we have done it. We hope that these bus conversion tips have helped you to get it right the first time, and avoid having to do a whole new build like us. If you have any questions or comments, feel free to send them through 🙂

How to change a bus into a motorhome and register it in NSW

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Note; Please contact Service NSW, or an engineer for specific information, this is a guide only on turning a bus into a motorhome.  

We have a lot of people asking us how to change a bus into a motorhome, and the registration process. It seems to be one of those grey areas where there isn’t a lot of readily available information. Starting from scratch with a bus can be daunting, and not knowing where to start, or what to include in your conversion can be costly if not done right. So we thought it was time for a post to help anyone looking to convert a bus to a motorhome, and then to register it.  

This post will focus on converting a bus to a motorhome from scratch. There are a lot of variations though, and we will try and answer some of these towards the end of the post.  

So, you’ve gone and bought a bus (Yay!), and now want to change it to a motorhome and have no idea where to start. The first thing we recommend is to get familiar with the requirements of a motorhome.  

So, what are the minimum requirements for a motorhome in NSW? 

  • Seats and a table 
  • Sleeping areas 
  • Cooking facilities 
  • And storage areas 

And, what are the basic steps I need to do to get it registered? 

This is a quick guide for what steps you need to take with a more in depth breakdown below. This is based on an unregistered bus with variations to this at the end of the post.  

  1. Contact your engineer to confirm your requirements for a motorhome, and anything specific your engineer of choice may want done.  
  2. Plan and complete your fit out. Make sure you meet all NSW requirements (below).  
  3. Take your bus to a weigh bridge for certificate.  
  4. Take your bus to the engineer so they can check all requirements and compliance is met. They will put a compliance plate on once complete.  
  5. Finally its time to take your bus for a safety inspection at an Authorised Safety Inspection Station (blue slip for vehicles under 4.5 tonne, or brown slip if over 4.5 tonne).  
  6. Purchase Compulsory Third Party insurance (green slip).  
  7. Attend Service NSW with all paperwork, proof of ownership, and any number plates on the vehicle. Fill out an Application for Registration, purchase new number plates, and register vehicle.  

Done!  

Please note, even though your bus is unregistered, you are allowed to drive it for the purpose of registration to the closest available inspection station . If you are not going to the closest, you should obtain an Unregistered Vehicle Permit from your local Service NSW.  

So that is a very basic guideline of what needs to be done to register a  converted bus into a motorhome. Of course, things are rarely ever as simple as we want them to be! So let’s get into some specifics.  

What do I need in my motorhome to make it compliant? 

Everything in the above list of minimum motorhome requirements needs to be rigidly fixed to the vehicle. However, you can have a table which can be folded down, or converted to a bed.  

Safety –  

The first thing an engineer will look at is the safety requirements. Everything must be fitted or installed so that it cannot cause damage or harm to someone. This is while the vehicle is both stationary, and moving. For example, you cannot have sharp edges, or items which will go flying while you’re driving and you cannot have any holes in the floor (we got caught out with this one!). All tables and chairs need to be installed so they cannot move or dislodge.  

Sleeping Berths –  

When it comes to sleeping areas, a very important requirement is that you must have at least one seat, per sleeping berth. So for example, if you have 4 beds in your bus, you must have 4 seats to use while travelling.  

Seats/Seatbelts –  

Seatbelts are important and something the engineer will definitely look at. If you are using a seat that was originally fitted, and in its original position, you do not need to make adjustments to any of the seatbelts. However, if you move any of the seats, or make any sort of adjustments (for example, change to captain’s chairs, or recliners) then the vehicle needs to be fitted with new seatbelts that meet compliance.  

Seatbelts cannot be fitted to a non-designated seat.  

Doors –  

In NSW, a motorhome must have an outward opening door on either the left hand side or the rear of the vehicle.  

So those awesome bi-fold doors? No good unfortunately.  

There are a few options here however; you can replace the bi-fold door with an outward opening caravan door, or you can modify the existing bi-fold door with different hinges, and by welding the 2 pieces together to make it a bi-fold door.  

A door that slides on the outside of the vehicle is fine.  

There can be no obstructions to the door, and it must be easily accessible in case of an emergency.  

Gas Appliances –  

Any gas appliances, such as ovens, stoves, hot water systems, heaters etc, need to be installed by a licenced gas plumber. You will need to get a certificate for the appliances installed. Your gas plumber will also need to provide a gas plate which he will attach to the vehicle which states it meets the gas regulations. This paperwork will all need to be provided to your engineer to be compliant.  

There are certain requirements with gas that are very important in your floor plan. For example, the gas bottles must be in a completely sealed box and only accessible from outside of the vehicle. Also, they cannot be within 1.5 metres of any ignition source. So this means that you need to have a gap of at least 1.5 metres from your gas bottles to your stove, and hot water system.  

Electrical Appliances –  

If you are having mains connection in your bus, your electrical installations needs to be done by a licenced electrician.  

You must get a safety certificate from your electrician stating that the work is compliant to motorhome standards. This is then taken to your engineer as well.  

12V and 24V wiring can be done by yourself, however if unsure, please contact an auto electrician.  

Ventilation –  

This is one where we got caught out and had to make a last minute adjustment!  

Depending on the size of your motorhome, depends on how much ventilation you must have.  

The standard rule is that at least half of your windows must open, you must have another source of ventilation (for example, our caravan door has a permanent vent to allow air), and you have to include either two whirly birds, or a roof hatch towards the rear of the bus.  

We didn’t realise this, and a few days before we were booked into the engineer we called to clarify we had everything and realised we did not have a roof hatch. Luckily there was a caravan shop close by we could get one and put in in time.  

Toilets, Sinks, Showers –  

Any toilet installed in a motorhome must be emptied into a tank. So this means, it cannot just go straight to the ground!  

The tank must be vented to the atmosphere.  

Any sink or shower needs to drain into a tank that also vents to the atmosphere. It cannot drain into a toilet, or the same tank as the toilet waste goes into.  

TV’s –  

This might be a small thing, but still important.  

A TV or visual aid cannot be installed somewhere that can be seen from the driver’s seat and needs to be securely mounted. It also cannot obscure the driver’s vision, or get in the way of movement in the vehicle. In other words, it cannot be a distraction!  

This does not include GPS.  

Fire Extinguisher –  

Every motorhome must have a compliant fire extinguisher mounted no more than 1.2 metres from the floor in the living space.  

Smoke Alarm –  

A compliant smoke alarm is a requirement to be passed by the engineer. It is also a good idea to consider one with a CO2 monitor.  

Standard vehicle requirements –  

And then there is all the other standard vehicle requirements you must be compliant with to change a bus to a motorhome.  

For example, all vehicles need to be within a certain width, and height and not have too much rear overhang.  

Every vehicle must be right hand drive and within its weight limits.  

All the lights and reflectors must be in working order and windows must be transparent with compliant tint.  

Tyres need to be the correct size for the vehicle, and have plenty of tread.   

So now that that’s out of the way, what are some of the variations? 

My bus is already registered –  

So you have bought a bus that is already registered. That is perfectly fine and not much different in terms of converting to a motorhome.  

Make sure to attend a Service NSW centre to pay and transfer the bus into your name. You have 14 days from the date of purchase to avoid being charged a late payment fee.

You can then follow the above step by step process up to step 4. After this however, once you have your compliance paperwork from the engineer, you can take this, and your registration papers to a Service NSW centre. They will update the information on their end and change it to a motorhome.  

They may still charge you a fee as there may be a difference in the registration cost from a bus to a motorhome.  

You may also need to contact your CTP company and advise them of the changes.  

My bus is coming from interstate –  

That’s okay, if it is coming from interstate, the process is exactly the same as if it were an unregistered vehicle in NSW. You will however need to surrender the interstate plates when you go into a Service NSW centre.  

If your vehicle is registered when it comes from interstate, you have 3 months to change it into your name in NSW.  

I have purchased a motorhome from interstate –  

The first thing we would suggest here is to contact an engineer in NSW.  

As the motorhome is coming from interstate, it may or may not be compliant with NSW motorhome requirements. In this case, you may need to make adjustments to your motorhome, then attend the engineer to get a NSW engineer certificate.  

You would then attend a Service NSW registry to complete the interstate transfer process. You will need to provide proof of purchase for the vehicle, as well as surrender the interstate number plates.

What if I want to decrease or increase my GVM? 

If you want to change your GVM, or are concerned with your weight, it is really important to keep this in mind throughout the process of your build, and speak to your engineer.  

The situations where a motorhomes GVM can be changed are very limited.  

The most common thing people would do here is decrease the GVM so the vehicle can be driven on a different class of licence.  

We enquired about this with our engineer originally, and they said they could, however would need to make an adjustment to the springs on the bus. We opted against due to cost, and decided to keep the extra weight allowance just in case.  

So, that’s it!

So that gives you an expanded list of requirements for a bus to be changed to a motorhome in NSW, as well as a guide to getting it registered. A lot of the states are similar but do have different requirements.

It seems like a lot, but as long as you know what you are expected to do, it makes the process a whole lot easier. There are definitely a lot of variations, and most certainly things we have not covered here. So again, when in doubt, contact your engineer or Service NSW for clarification.  

And good luck!