On Saturday morning, we left Zephyr in our rear view mirror as we departed Elkhart in our Mini Cooper, like nervous parents dropping our kid off for summer camp.
This summer, Zephyr will be attending Camp Master Tech where she will be whipped back into shape.
Four years ago our GM 4106 vintage bus conversion came into our lives – a fully converted former passenger highway bus, that we’ve been slowly working on ever since to make our very own. We’ve done it all while living and traveling full time, reaping the rewards of full time RVing while building our dream mobile home.
Our thought process was that it would be more fun and more economical in the long run to start with solid, sexy and livable bones, than starting with most any mid-class modern Class-A that we’d need to renovate anyway to meet our tech demands.
Over the years we’ve tackled a kitchen remodel, new floors, new front seats, building in dual desks, lithium ion batteries, solar panels and electrical upgrades.
This summer will likely trump them all in terms of time and costs as we approach tackling most of the major projects remaining on our wish list. But all total, we still feel ahead than if we had gone the standard Class-A route. And we’ll end up with a coach that is 100% uniquely us.
Here’s a quick video we took before we left Elkhart going over all of the major projects we decided upon while visiting Master Tech:
If you don’t have the bandwidth to watch or prefer old-fashioned text, here’s a quick re-cap of the projects on the list:
Repainting – This is the main project and what is driving all of the others. All of Zephyr’s blue and white paint will be stripped off, primed and then prepped. She’ll receive a new paint job with at least a double clear coat for protection.
We’ll be keeping almost exactly the same paint scheme however – retaining her sweet bus look.
There will be some minor body work done in the process, including some rust remediation and maybe some fun surprises :).
July 22 Update: The repainting is well underway! Zephyr has been stripped, the primer applied, the roof painted (with a single stage paint that is less slippery).
New Windows – Our bus came with RV single pane windows, that are honestly in pretty bad shape. They all need to be taken out, cleaned up, resealed and rebuilt. One pane is has plexiglass instead of real glass. They all need rescreening. Before opting for rebuilding the existing windows, we got a quote from Penisula Glass to have new modern dual pane windows made for us – and it wasn’t all that much more expensive. We opted for the upgrade, and have new windows in process.
Anyone in the market for some older single pane windows for your own conversion? We have some ready for a new home.
July 22: Windows should be shipped by the end of this week. Perfect timing to arrive when the paint job is done.
MCD Shades – We were on the fence about ditching our awesome Tiffany Tilt Mini Blinds (which we can’t find any modern day reference to). They’re mini blinds that actually close completely private. But they are difficult to clean and they all need to be re-strung. We’re installing Day/Night MCD Shades in the living room, and a Day Shade in the front windows. One of the living room shades will be installed so that the night shade can double as a projector screen for movie watching (gotta love double duty!). We’re keeping our blinds in the bedroom, as we love the flexibility of ‘cracking’ open a couple top slats for ventilation, while keeping feeling somewhat private.
Awnings – One of our awnings started ripping apart a few miles ago, signaling it was time to replace them. We haven’t yet decided on just what we’ll replace them with- we’re still in research on that. The biggest hurdle is our curved roof, and we’re in talks with several companies about the most reasonable option to get a lateral arm case style for the patio while minimizing bracket fabrication time. All of the window awnings should be a simple matter of either replacing the fabrics or getting new units.
July 22 update: We’ve decided on the Dometic 9500 Power Case awning for the main patio and new Dometic window awnings. Master Tech will need to fabricate a pretty extensive bracket for the main awning. The awnings are in production right now, and should be shipped soon.
Hydronic Furnace & Hot Water Heater – Our dream has been replacing our propane/electric 10G Suburban hot water heater with a hydronics heating system. We always thought diesel was the way to go, given our fuel source.
However, the PrecisionTemp Jr. really caught our eye as a lower cost of entry and less maintenance over time. After a lot of discussions with current owners – we decided to go with it. This unit, which will be installed in one of the bays, will provide our hot water, engine pre-heating, bay heating, on demand hot water for tea, interior heating via heat exchangers that will be run throughout the coach. With dual pane windows and lots of insulation we’ll be ready for some winter camping!
Which means… we’re bringing propane BACK into our coach. Yup, we went propane free after we got the bus because the installed systems were completely unsafe, but now we’re doing it right with thought and attention to safety.
July 22: The PrecisonTemp installation is well underway! In other plumbing news, in evaluating our existing holding tanks and the work they’d need to reseal and such, MasterTech presented us with the idea of new much larger tanks (current estimate is 150G of grey and 75G of black). We’re going with it – hello endless boondocking!
Ditching the Generator – We already announced we’re getting rid of our 7500w diesel generator (it sold quickly!) – it’s just overkill for our needs. Instead, we are going with a much smaller propane powered unit (probably just 2500w, enough to top up the batteries or run an A/C if there’s not enough sun to keep our solar happpy), that will be installed in our spare tire bay.
Why not go with a diesel generator since we use diesel for our bus anyway? There are none small enough to fit in this bay and they are much more expensive. Since we’re bringing in propane anyway for the Precision Temp, this seems to be a great solution for us when we consider generator use an infrequent need anyway. Plus, propane is cleaner burning and requires less routine maintenance – more suitable for our anticipated very occasional generator use.
We’ll installed Propane tanks in the previous generator bay which is well ventilated and away from other things that can cause calamity. There will be a quick connect mechanism that allows us to hook into other sources of propane should we need them.. such as a refillable 20 lb ‘BBQ grill’ style tank, so we don’t have to take the whole bus for a fill if we don’t want to.
July 22 Update: The old genset is out, and MasterTech has confirmed that the Onan 2500w Propane generator will fit just fine in the spare tire bay – one is inbound. The bay will be sound proofed as well.
And this all.. so that we can turn the old hot water heater cabinet which was located in the hallway into a dedicated cat litter chamber! Kiki is finally getting her very own private place to poop. This will make the entire household happier.
Everything is all about the cat after all.
Whew.. it was a very long and eventful week at Master Tech. We’ve been in super charged turbo mode for weeks on research and preps.
But now we leave all these projects in their capable hands… and on Wednesday morning we board our first train, starting our big Alaskan adventure!
We are exhausted beyond belief, and just can’t wait to finally reach our first cruise ship balcony cabin and indulge in some true down time. It’s been a long time coming.
Progress Reports:
August 14, 2015: Bus Renovation Progress Report: A Riveting Tale of Why We’re Way Behind Schedule
August 22, 2015: Bus Renovation Progress Report #2: Week of August 17
Do you run a dehumidifier? Just wondering cause Wife and I are doing a skoolie and are a bit concerned about condensation. we will be mostly in florida (humid) but also maybe go to nevada to dry it out if needed 😉 Wonderful blog you have by the way. So informative!
We’ve never felt the need for a dehumidifier.. and we’ve spent a lot of time in Oregon and Florida. Know others who swear by them however.
” The Last Resort” wants to know about your Viair 450 as that has been on our list for several years
So far.. impressed with it, given the limited amount of use we’ve gotten in the shop. 🙂
I wish you well with your propane decision, however I’m worried for you. Yes, I’m an all diesel guy, with hydronic heat, engine pre heat and gen set, AND roof solar. However the cost to heat my 600 sq. ft well insulated cabana in a mild temp area of Idaho with propane/hydronic has been a surprise and not a nice one.
600 sq ft in a RV? That’s a lot to keep to temperate. Our bus is about 280 sq ft, and very well insulated. We also tend to follow the weather, and consider our options for heating & cooling to be for those times we get caught a bit off guard by changing weather patterns. Last winter, we had a couple weeks in the 20s/30s/40s while boondocking, and did fine with a single ‘Mr Buddy’ propane space heater. When we have electric hook-ups, we also have electric heaters.
They should have treated you better, thats bad business. CAnt wait to see your bus all done. You 2 deserve it!
Hey fellow 4106 owner here, I called peninsula and they said they did not have dual pane window for the large side windows? Are you guys getting the side windows from another vendor?
Thanks
Shane
We don’t have the original swoopy windows. The new driver & passenger windows will be single pane however.
Ok cool thanks, I love your site thanks to you guys for sharing!!!
Here is a pic of our bus, we have a 6v92 and auto trans we got it about 4 months ago, so far so good ….
https://goo.gl/photos/QkzJqT6s1jfb2DPHA
That looks like a pretty bus – and an awesome engine. Are you planning to full time in it?
See you out on the road!
– Chris
We found your video chat “what does it cost to full time RV” on YouTube. I can’t tell you how much we appreciated hearing from experienced, honest, intelligent and professional folks who told the truth in such an organized way. Your personalities shone through which kept it all very real. We will be tuning in again soon. Thank you for the work you so obviously put into this–you are definitely helping people like us make some thoughtful decisions. Look forward to seeing the finished bus project. Enjoy your break in Alaska, well deserved I’m sure!
Wow! What a lot of great upgrades! Good thing you are leaving town. Can’t wait to hear how it looks and feels when you get back. We opted for dual pane windows in our 5er, because our prior RV would just pour condensation off the windows, when we were camping in the cold, especially. It has made a huge difference. We had a little condensation once in the past 3 years, and that was on a small window right by my face when I woke up. Maybe 3 drops. With our single panes, that would have been raining moisture on me. I think the dual panes have made more difference than any other upgrade we have.
Have a great time in Alaska!
Sounds awesome … Look forward to photos of the new bus as well as your trip to Alaska….
One comment on the PrecisionTemp. I installed one of their units in our Sprinter conversion. For showers, the thing is totally awesome: long showers, hot, hot water, as much you want, subject to the limits of your water supply. Love it (even though we don’t actually use the van shower very much).
For sink use … ugh, different story. Filling the sink: excellent. For rinsing with mild/warm/hot water: a medical emergency waiting to happen. Turn off the hot water. Wash dish(es) for 30 seconds. Heat exchanger remains hot. Water in plumbing wrapped around heater exchanger continues to heat up. And up. And up. Turn on hot water to rinse. Super-heated steam. Yes, really.
I plan to put in a small 3-5 gallon “hot water holding tank” above the sink, and will use this for “rinse” or “on-off-on-off” style uses of hot water.
Have you talked to Precision Temp about this? We have several friends who have one, and none have had an issue like this. I wonder if there might be a problem with the mixing valve.
Let us know if you find a solution for you.
– Chris
I’m happy for all three of you and the updates you are doing to the Zeypher! I enjoy reading your blogs! Keep up the good work on your blogs. One question-Where is Kiki staying, while you travel to Alaska? Have safe travels to the both of you!
Kiki is staying here in St. Louis with her grand-meow 😉
I’m surprised you are bringing back propane. The rest of it sounds wonderful!
I think it’s kind of cool that they looked at all their options and then didn’t “not take” the propane one just because of a previous decision.
Propane can be hard to beat for certain things (although of course there are always other options). Diesel heat and etc. are really nice, but typically require more maintenance.
One good thing is that a brand new propane system will be installed properly. Sounded like the original system was not.
I did a bit of reading on the Precision temp website – not for my rig right now, but I always like to read about the options.
I’m sort of “rearranging” my propane and electrical layout. Essentially keeping propane for cooking and heating, but going to a compressor refrigerator (to be mostly supported by solar). This leaves me a generous sized propane tank for heating (since it will no longer support the refrigerator).
I can’t wait to see the “re-born” Zephyr!
We were surprised too that it turned out to be the right decision for us. We never said we are anti-propane, just anti-OUR-old-propane setup. It was really really unsafe.
The kiknator will appreciate the upgrade
We hope she approves.. it is all about her, after all.
Here’s hoping you guys have a wonderful Alaska journey! Send lots of photos!
We’ll be taking lots for sure… hope to find ample bandwidth to share them.
How great to get so many big projects completed at one location – and even better to be out playing while the work is getting done! My boys and I took a 4 week road trip while the kitchen remodel was being done. It was wonderful to return home having missed all the dust and drama! Kiki is a great motivator :-))
We really are blessed to have Master Tech as a resource who can tackle such an array of projects at once. And, a place we can trust to leave our baby behind while we embark on other adventures.
Zephyr is an incredible work in progress–a project for the young, as 40 is for the RV crowd! We eagerly await the reports on your Alaska journey and the tech reports when you re-inhabit your “new” bus! Good luck and keep it comin’.
It’ll be so much fun to move back into our new bus.. and looking forward to sharing the finished results.
lolololol in the video “maybe it’s time to go to Thailand for 6 months!” nice.
It’s been on the list for a long while… we’ll get there with ya!
Sounds like a couple of serious tasks on that list. You’ll have the RV Techs busy and on their toes while you relax on that cruise deck. 😉
Looking forward to the posts of your Alaskan adventure! Enjoy
Yup.. they know when we return, and know we’re awaiting progress reports from afar 🙂
After removing the propane hogging furnace in my RV, I realized the fixed mount 80 lb propane tank was overkill. It was also difficult to find a convenient place to refill it. So I removed the tank and replaced it with a mount I made that holds one standard 20 lb tank. I also keep a second tank as a spare in another compartment. Now I can stop nearly anywhere I want for a refill. One tank last a few months of stove, continuous water heater, and vent-free heater use.
I also sold the old tank online for $150.
I love tweaking my motorhome into my own custom solution. You guys clearly do as well.
We’re also going with removable/portable tanks to give us more options for refills & swaps when needed. We’ve had that on prior setups, and loved the flexibility.
I installed a Precision Temp RV-500 continuous water heater 4 years ago. It’s ran like a champ. I never run out of hot water. And it uses very little propane. The model with hydronic heating is very interesting.
Awesome to hear..thanks for sharing.
But of course Kiki’s needs are the nubmer one priority!
And number two 🙂
Look forward to seeing some pics of the old girl all spiffed up. (The bus that is 🙂 Have a safe trip and we eagerly await hearing all about your next adventure!
Thanks… we’re eager too. It’ll be nerve-wracking being so far away while it’s all happening.
I’m so happy for you! It feels good to get things rolling, pardon the pun, lol I hope all goes uneventfully and smoothly. Have fun on your adventures!
Nice pun 🙂 Thanks..and cheers!
Can’t wait to see how it all turns out! And glad to know KiKi is getting her own special space. Enjoy that cruise ship balcony and your down time!
We will indeed.. and hope you guys have an amazing east coast summer!