2003 Ford E550 Shuttle Bus Almost Complete Conversion

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by Jeremy Prudhome
Published: July 5, 2022 (2 years ago)
VIN Number

YOU DON’T WANT TO MISS THIS OPPORTUNITY, IT WON’T LAST LONG! Direct injection diesel, no DEF required. This bus was owned by one church that completed regular maintenance prior to conversion. All the hard work has already been done and this conversion is near done with plenty of room for you to complete with your own finishing touches. Perfect for a family of 4 with TONS of storage space throughout for all your travel needs. Whether you are a weekend warrior or want to live in Dorothy full time, the storage space is far more than you will find in any manufactured RV (We have looked and confirmed this). Dorothy was converted during the Covid lock downs and with current busy schedules we don’t have the time to finish our dream. We want to pass Dorothy on to someone that can enjoy her as much as we wanted to.

This bus was stripped down to the sheetmetal, roof, and Wood Subfloor and built from the bones using solid wood construction throughout. All leaky windows were sealed, all mold and any rust behind original walls was treated and removed. There is no particle board or cheap materials anywhere in the build. There are spots on the passenger side of the bus where the original church signage was that is peeling. Spots have been cleaned and primed over to prevent rust. Undercarriage is very clean and has never been used in the north so no salt or rust damage.

I have done all of the work myself and have not spared any time or expense for the work I have done on this conversion. I would be glad to discuss any parts of the build with serious buyers and I can share pictures of the build process to confirm items listed in this description. Feel free to call or text.


Cab and Cabin Measure Approximately 31’ Long and 9’ Tall

GCWR 20,000 Lbs / Trailer Tow Weight 10,000 Lbs

Original floor in great shape and overlayed with ¾ foam insulation under new ¾ plywood.

Walls are insulated with 1’ foam insulation, covered windows are insulated with 1/2” foam insulation.

Ceiling is insulated with spray foam insulation and ceiling height is 6’ 4 ½ tall

Roof has been repainted with Henry Solar Flex Elastomeric roof coating and all joints have been filled with Dicor Lap Sealant

Walls are made of Revolution Ply 5MM Poplar sanded plywood on top of 1×3 & 1×4 furr strips

Studs in walls are 2×3

Wiring ran throughout is 12a Ancor Wire, 120v Romex, and 240v Romex to AC.

120/230 Panel is Square D 12 space / 24 circuit and is wired for 50 amp service

12v Fuse Block is 6 circuits with ground

12v LED dimmable lighting throughout entire bus plus additional lighting throughout. No Dark Spots

Pioneer Minisplit Air Conditioner/Heat pump 18,000 BTU 19 Seer 230v Diamante 16ft kit with custom built rack for outside unit mount on back of rig (cools and heats 800-900 sq ft)

Water lines throughout are hot/cold PEX with clamped fittings throughout.

All interior walls and trim have been primed and painted. Walls are painted in Agreeable Gray and trim is white.

All appliances and materials are brand new and have never been used

CD Player with Bluetooth and wired for 4 speakers placed in 4 corners of the cabin

Comes with Spare tire & mount

Custom Made heavy duty cargo basket for generator, bikes, grill, etc… mounted on the back is 8’w 3’deep with 7” Raised sides and multiple tie down hooks. Made from 1/8” square tubing on top of 2×2 square tubing bolted to frame. This thing is SOLID!

Features that have been installed:


3’x8’ bolted on heavy duty cargo basket on back of bus

(2) 12v LED Flood lights (wired for all 4 corners, 2 installed and 2 included to install)

Color cameras on both sides and rear with Monitor in driver cab

(5) 120 outdoor plugs on all 4 corners and rear above basket

230 Disconnect for AC

All exterior running lights have been replaced with LED running lights except headlights

Water tank drain

50a Electrical hookup

Locking gravity/city water fill


4 Reclining seats bolted to frame and floor with added seatbelts

Custom Made kitchen pantry cabinet with hardware

Storage under/behind seats great for shoes and other larger items

USB outlets for charging

Decorative 12v accent light over table area

120 Plug


MaxxFan Deluxe 7000K Elec Pwrd 12v 14×14 With Remote/Rainshield/10 Spd

Custom made kitchen cabinets primed and painted dark blue (still needs touch up/finishing paint)

Stainless Steel Magic Chef Refrigerator/Freezer 10.1 cu ft.

12v Liquid Propane/Carbon Monoxide Detector

Drop In 25” black granite deep sink with swivel removable faucet/sprayer

Natural Butcher Block counter top with tons of space at 6’ 8 ½” x 2’ 2 ½” if you count the glass over the cooktop and cover over sink

Greystone 12v/LP range and 3 burner cook top with blue LED lighted knobs

120 Plug


2 solid wood bunk beds as sturdy as the entire build with 12v reading touch lights and blue night lights

Bunks are 28.5” wide by 78” long – Brand new 30×74 memory foam mattresses new in the box included

Smoke detector with LCD Display

Tons of storage space under bunks

120 Plug

BATHROOM 37d x 78 ½ w

Shower 35”w x 24 ¼ d x 6’ 2 ½ h – Walls made of concrete backer board and completely sealed with Red Gard waterproofing membrane – Shower pan is 36×24 L drain and all plumbing is on right (hall) wall with single handle water control and luxury shower head

Gray vanity with shaker doors, hardware, black faucet

120 Vanity light

(2) 12v dimmable LED lights (one in shower)

Decorative storage wire basket for toiletries

(2) 120 Plugs


120 Plugs in each closet

Shelving throughout wardrobe closet and room for rod to hang clothes

Wardrobe Closet is 28w x 30d x 76

Electrical Closet is 16 ½ w x 30 x 76

Dedicated electrical closet with room to mount electrical system of your choosing – already contains

120/220 Panel is Square D 12 space / 24 circuit and is wired for 50 amp service & Fuse Block with 6 circuits and ground

Rack for 4 Batteries


Queen Lift bed with water tank/system under and 2 ½’ x 6’4” of storage underneath (10” Cool Gel Foam queen mattress new in box included)

Built in headboard (blue to match kitchen cabinets) with shelving and 2 storage boxes at head of bed

(2) 12v reading touch lights and blue night lights

WATER SYSTEM (Mounted under bed in bedroom)

Fresh water fill City/gravity fill

100 gallon water tank

Excel ventless LP water heater 1.5 GPM

Shut off valves

One way check valves

Beech Lane dual water filters

Water Pump Shurflo 3.0gpm 12v

Shurflo Water Strainer

Shurflo Water Pump Silencing Kit

Shurflo Accumulator tank

Pex hot/cold water lines with crimped fittings throughout


(2) additional LED exterior flood lights for rear of bus (already wired)

100 gallon gray water tank (to go in space under cabin where old AC was removed)

Graywater tank components & parts

29.3 gallon Under Mount YSN-293 Horizontal Propane Tank (to go in space under cabin where old AC was removed)

Lp Tankless water heater vented Camplux 25a 55psi 3.0gpm (Extra Water Heater in addition to installed water heater currently in bus)

Graywater dump valve

Plumbing Sewer Vent Cap

26” Sewer Hose Carrier

Refrigerator Side Wall Vent 20” (Optional)

Roof Caulking

Butyl Tape

Roof Patch Roll

Pro Flex Brush Sealant

Dicor Lap Sealant

(4) Super Struts and hardware for Gray water tank under chassis mount

LED Light for inside shower

10” Cool Gel Foam Queen Mattress

(2) 30×74 Memory Foam Mattresses for Bunks

50”x25” Butcher Block Table to match Counter Top (Uncut)

27” Floor mount table leg for Table

Barn Door Hardware

Cover for Double Door Closer Mechanism

Tow Hitch materials to connect to custom cargo rack


(4) Lion Energy 105Ah Lithium Iron Phosphate Batteries with level indicator (no need to vent)

10,000 Watt All Power America Dual Fuel Gasoline and/or Liquid Propane Generator

19×19 Natures Head Compost Toilet W/Spider Handle

Generator Cover

50’/50a Leisure Shore Power Extension Cord

Journeyman 50a to 30a dogbone reducer

Rhino Extreme 15′ Crushproof Sewer Hose



Lithium Specific Isolator

Battery to isolator fuse box

12v fuse block

120v fuse block

Optional systems manager


Transfer Relay

Jumper wire for battery to battery

(2) Light switch plate covers

Drain lines from both sinks and shower once gray water tank is installed

Propane Adaptor

Propane Regulator

Propane Hose Assembly

Propane Aux Tee

Range Vent Hood

Shower Wall Material (Your Choice)

Shower Drain

Cab Ceiling Cover (Can Build Storage in that Space)

Wall/Ceiling Transition Cap Throughout

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