2001 Chevy Express G3500 Shuttle Bus Partial Conversion

2001 Chevy Express G3500 V8-495 8.1L-PRICED FOR A QUICK SALE

I am selling my partially converted shuttle bus, I have traveled and lived in it most of this year but I am starting a new career shortly that won’t be conducive to “bus life”. Finish it off to your final specifications and preferences after most of the hard work has been done :) I only have 10 max photos uploaded but can send more and videos as requested. Please read to the end as most questions can be answered below.

It is registered in South Dakota and has been converted to an RV on title. I own it free and clear with no title issues.

Mechanically, I had a lot of work done on it since February when I purchased it. And I have all the paperwork to corroborate as well.

1. New battery
2. Six (6) new tires
3. Replaced ground strap
4. New fuel pump
5. New power brake booster
6. New starter and spark plugs
7. Replaced #3, 4, 7 and 8 fuel injectors
8. New throttle body
9. Rebuilt the drivers AC system, rerouted AC lines from rear AC which was removed
10. New brake pads
11. New belt
12. The AC compressor failed this fall and I replaced it with a delete pulley, I don’t use the AC as I’ve been way up north most of this year.
13. I’ll change the oil again before it goes to a new home

Electrical-12V system 

(1) 100 Ah LiFePO4 Battery. 12.8V Lithium, 10000+ Deep Cycle, 1280W.

12 way fuse block

1000W Pure Sine Wave Power Inverter

(2) 3 Port USB outlets. One is mounted in a wall and the other is up front to be installed in the drivers console.

(3) Blue Sea Systems Dash sockets. Two are run to under a kitchen cabinet for fridge and freezer and one is run to inside the bench seat. I used that one for a 12v vacuum cleaner.

(1) 12v vent fan mounted in the half-wall of the bed frame to vent under the bed and where the electrical components are.

(2) Swivel RV puck lights in the cab ceiling, the switch is mounted on the wall with the USB port.

Victron Energy BMV-712 Smart Battery Monitor. Mounted on the wall with the light switch and USB port. Connects to the app and has never had an issue.

(2) Brass and black battery operated wall sconces in the main living area. Remote included.

(2) Art deco style black and linen battery operated wall sconces above the bed. Remote included.

Maxx Air Deluxe 10 speed reversible fan w/remote (00-07500K). Remote included.

Battery operated strip lights under the kitchen upper cabinets. Remote included.

With the ceiling currently exposed it would be easy to run more recessed puck lights along the length of the bus and tie into the current light switch.

Solar System

(2) 100 watt Renogy solar panels-monocrystalline silicon

(1) 20A Rover MPPT charge controller

Panels are mounted on the roof with raised molded mounts which are drill-free and bonded with sealant. Have had zero issues with this mount and chose it so I wouldn’t have to drill into the fiberglass roof.

The cables are routed from the panels, through the double cable entry gland down into the rear of the interior of the bus and connect to the charge controller under the bed. I have left one piece of wall exposed near the rear interior corner in case you need to do anything to the cables etc..When you have a bedspread or pillows on the bed you cannot see the exposed wall.

(2) Small outdoor solar lights by both the drivers door and the main door.

Build

I deleted five windows in the body and made two others half-windows. The walls and windows are insulated with a heat and sound deadening mat and foam board over that. The result is a quiet and comfortable living space.
The kitchen has two pre-built cabinets installed with stained butcher block countertops. The cabinets are painted Creamy Mushroom with custom brass pulls from Etsy. I have a hole cut for a 12” prep sink. I had a vessel sink before but it took up a lot of counter space. The kitchen faucet has a pull down sprayer. I’ve installed a Waterdrop under cabinet water filter, a shut off valve from the 30 Gl water tank under the bed and a SEAFLO 12v self priming water pump. I was going to install an Excel tankless on-demand gas water heater on the left side of the kitchen cabinet and a sealed propane box under the drop-in two burner cooktop but I hadn’t gotten to that project. I do have the cooktop cut out and dropped in though. And there are two three-tiered drawers from The Container Store that fit perfectly under the cabinets that I’m selling with the bus too.
Opposite the kitchen is a tall closet with a closet rod for hanging and two deep shelves and I’ve kept the Boxio toilet on the bottom shelf and will be selling with the bus. The closet door is solid maple and stained on the inside and upholstered on the exterior with a large iron handle from Crate & Barrel. Attached to the closet is a solid burled wood three-drawer dresser with brass knobs and individual locks on each drawer. It was a custom six-drawer dresser I owned and cut it down to fit in the bus. Attached to the dresser is a gray slatted storage bench from Wayfair. The hinged lid lifts on gas struts and the dimensions are 47” W x 18.5” D with a weight capacity of 400 lbs. I am 5’8 and am able to sit on it with my legs outstretched on it. The right side of the bench is attached to another tall closet and that closet wall has the light switch, battery monitor and USB outlet mounted. I have a small table top from the other half of the burled dresser countertop on an RV swivel table leg that can be mounted. I took it down because I was going to build a privacy wall between the cab and living space.

There is a small gap between the bench and the wall where I have the wires run so everything is easily accessible now for any upgrades or changes.

The bed is on a piano hinge lift mechanism and I have cedar tongue in groove slats beneath the mattress. I preferred that over a plastic interlocking system for airflow. The mattress is a full-size trifold memory foam mattress with a nonslip bottom and measures 73”x52”x3”. I sleep with my head to the left of the bus and I installed two wall sconces above my head and built a half wall with a hinge top below the sconces, almost like a headboard. It’s great storage for anything flat and it’s easy access for the water lines from the gravity fill to the tank. I built upper cabinets above the bed, the doors are matching to the burled dresser, and above the kitchen counter. I have four brass wire baskets that fit perfectly in that space. And there is a massive amount of storage under the bed alongside the water tank and electrical setup. And all the cabinets and drawers have the RV cabinet latches installed.

There still needs some work done on it so that’s why I am selling it AS-IS. I was reconfiguring the kitchen this fall to add the smaller kitchen cabinet and counter where my old fridge chest used to be, a Dometic fridge will fit perfectly in the cabinet but I only have my old chest fridge selling with the bus. I do not have the water heater installed yet so you can still upgrade the electrical to a 120v system if you’d rather go electrical than gas. And the fiberglass ceiling needs to be braced due to some sagging, I bought it knowing it had some old water damage but I didn’t brace it. Beginners folly..I do have the length bracing begun as you can see in the photos.

But with the ceiling exposed you can run more wiring for lights etc and finish the ceiling however you want. The roof has been primed and painted with elastomeric paint and for good measure I just repainted it with Flex Seal about a month ago. I painted the exterior body Sherman Williams “Muddled Basil” and the front cab just a satin black but it’s been too windy here in Oklahoma to spray a top coat.

I replaced the main door with a stained wooden house door and installed an electronic lock, and a magnetic bug screen. I had planned on replacing the door with an RV custom fit door but didn’t get to that. I replaced the windshield cowl cover and attached deer whistles as well.

The drivers console has had quite a bit replaced too but there are still a few pieces that need to be hunted down at salvage yards to complete it.

A few other things I’ll include with it:

1. Mr. Buddy heater
2. Jackery Explorer Plus 300W solar generator power station
3. Excel tankless gas water heater (It’s in storage in another state so I’ll have to ship to you)
4. Extra electrical wire, battery cables, fuses and connectors etc
5. Extra plumbing clamps, hoses, drains etc
6. Leftover flooring and paint
7. Outdoor rug
8. Hammock camping chair
9. Outdoor folding camping table
10. 12v car vacuum cleaner
11. Camco RV water tank filler w/shutoff valve and water filter
12. Collapsible flat hose
13. New speakers and wires
14. 5 Gl gray tank I used under the sink
15. Euhomy 12v 38 qt chest fridge
16. Blue Sea Systems Battery Switch
17. Fire extinguisher
18. Small cutting board and dish drying mat
19. Magnetic knife strip and knife set (mounted in kitchen)
20. 10 pack Tri-Lynx wheel levelers
21. Non-slip rug runner (in photos)
22. Reflectix window covers custom cut
23. Butane camping stove and canisters
24. Extra spice jars that fit in the spice racks on the kitchen wall
25. Windshield sun shade
26. Boxio portable toilet

It is drivable and all in good working order and ready for test drives and a new home.