Hi all, I thought I'd start this thread here as there isn't a section for builds/fitouts as such.

The bus is a '92 Mazda T3500. She was a school bus near Joondalup, Perth and the first job was driving her back to the Sunshine Coast, QLD. Sleeping on the rear bench seat wasn't too bad... but I froze my butt off the first 2 nights until I got to Broken Hill and bought a decent sleeping bag. Other than that it was a great trip, no hint of any kind of problem, no shimmy in the steering wheel, no flat tyres, just smooth sailing all the way. There was one kangaroo that I couldn't quite avoid, but considering how many I saw, I figured that was pretty good going too... though I'm sure he or she wasn't that happy about it :(

So far I've only removed the seats. Today I'll be taking care of some surface rust around the kickboards and hopefully starting on the bed frame, so maybe an update tonight.

Well done! Looks great so far. Looks in good nick too. I see by that first pic you did it hard coming across  but sure you will fit into the lifestyle well.

Looking forward to your progress reports and pics. 

Full reno happening there.

Ok, it doesn't look like much, but this is where there's the most work for the least visible payoff... the prep!

Just working from the wheel arches back in stage 1. The idea is to have the bed and boot finished with the rest intact so we can keep using it during the course of the fit-out.

Rear heater removed, probably re-position and reuse as it's a great system and it's there, so may as well use it :) If you're not familiar with them they're a fan and a little radiator that runs off the engine coolant.

Rust ground, converted and killrusted.

Old vinyl lifted and floor sanded and sealed with varnish.

Today I'll caulk all the corners and disused seat mount holes to make the boot water and dust tight, and apply another coat of varnish... then I'm ready for the bed frame.

I'm still on the hunt for a big access door for side entry to the boot. The Thetford #06 is close but just not tall enough... my max cut-out size is 1040mm x 590mm. The Thetford is good for length but is about 60mm lower than what I'd ideally like.

Aaaaarrgh!!! Didn't realise the caulking needs 48 hours to cure before I can put the top coat of varnish on 

Couldn't find the exact size access door I wanted so I went with the Thetford which has an opening of 980mm x 400mm, I bought that on fleabay last night. By the time it gets here next week I'll have the bed frame done and be ready to cut the hole and install it.

Pulled the hood lining out, just leaving the section over the ****pit. I checked under the insulation and there's not so much as a spot of surface rust anywhere! That's the upside to buying a bus that never had air conditioning

Never had Aircon? It looks like you have the aircon turned on though 

Your new camp mobile is starting to take shape nicely OB. 

Nope, in the early 90's air con was a luxury item... especially for a school bus

My advice to anyone looking at an older bus is to get one without... aircon makes condensation... which makes rust. This thing's roof is literally pristine, even the roof lining was immaculate.

The Thetford access hatch turned up yesterday... so did the rain

I've cut the inside panelling away, just need the weather to clear so I can finish the install.

The aluminium angle that's riveted to the walls below the windows is the frame for the bed base, which will be 17mm film face ply.

Hoorah!! Finally got a whole day of nice weather to finish installing the Thetford access door

It took a whole day, but well worth it. The boot under the bed is a whopping 1800x1200 so the original single rear door was never going to do. I love the fact that these Thetford doors allow you to use the piece you cut out as the infill for the door to maintain the lines of the vehicle, it's more work, but the look is great IMHO

That looks great. Well thought out. Keep the progress pictures coming.

Cheers DM, I'm going to put a piece of MDF sheet on the inside face, plus a couple of chains so I can use it as an impromptu bbq table

Lol... any time you're on the Sunny Coast just swing on by Doug

As the man in the steak knife add said... "but wait, there's more"

Just need to get some S/S chain and shackles and she's a done deal!

You betcha Doug, a couple of chains with snap clips to hold it up. The little 2 burner BBQ, kettle etc will be in a box just inside the hatch, so when making a quick stop for a cuppa it'll be set up in a jiffy

Thanks W&S... plenty more to come

The finished product

Now to finish the bed...

As usual looks great OB. I use one of those toasters all the time, even indoors, much nicer taste. One thing, I have it turned the other way around, with the mesh down 

 Doh... good pick up there Doug, I use the other (correct) way as well, just threw it on there for the pic

How's your back?

Still got it mate, enough for now as I don't want to take things 

Thanks jade46, I did see that post, but we're going mostly electric. The odd time I want to cook an oven meal, it'll be in a camp/dutch oven.

Bed base is done... except for s and caulking the corners.

Couldn't resist, I had to throw the mattress on to try it out, imagining I was looking out over a beach, creek or mountain vista

The mattress consists 2 layers, the bottom being 10cm high density memory foam which was stripped out of an Oztrail self inflating mattress and the top layer is a 7.5cm medium density memory foam mattress topper. The bed base is a sheet of 19mm construction ply with no centre support, just the aluminium angle on the four sides. The result is an uber-comfy but very supportive bed... might even sleep on it tonight

Yep... not to mention a lot more $$$$

I've actually got a few bits and pieces in the garage to fit. A stereo, outside shower box/hatch, remote central locking kit and some LED lights. Just getting some work out of the way so I can spend a couple of days on her later in the week

Look'n good there Steve. No sleeping on the job now that the bed is finished   I know, that's why you did that first really.

I thought you might put a door on the front of the base to access from inside