How We Ended Up With a Bus
Honest answer: we watched too many skoolie YouTube videos. But also — we needed more space. After 18 months full-time in a Sprinter, we both agreed that one more winter of bumping elbows in 80 square feet of living space was one too many. A bus felt insane. We bought one anyway.
The Buying Process
We found this bus on GovPlanet — a government surplus auction site. The listing had 11 photos and a brief mechanical inspection report. We drove 4 hours to inspect in person before bidding. Here's what we looked at on the inspection:
- Started cold without excessive smoke
- Drove smoothly — no slipping in the Allison transmission
- No visible oil leaks under the engine compartment (engine is under a hatch inside the bus on a Type D)
- Air brakes pressurize and hold properly
- Pulled two sections of floor mat to inspect for rust — found surface rust only in the spots we checked (more on this later)
- Body panels mostly solid, some minor dings on the rear corner
- School district records showed oil changes every 10,000–12,000 miles, consistent coolant service
We bid on GovPlanet and won at $7,200 — about $2,000 under our maximum. Paid a $200 buyer's fee plus $180 to have it transported to our driveway on a flatbed (couldn't get it commercially insured instantly for driving). Total bus acquisition cost: $7,580.
Week 1: Demo Day (Days)
Seat Removal: 72 Seats, 6 Hours
School bus seats bolt through the floor with two 1/2" bolts each. That's 144 bolts for 72 seats. Many were corroded and needed penetrating oil and an impact gun. We soaked them all the night before with PB Blaster. Total time: 6 hours for two people. The seats are heavy — budget for a way to move them. We stacked them outside and listed them on Facebook Marketplace. Sold 60 of them for $15 each. That's $900 back — not a bad offset.
Floor Removal: The First Surprise
School buses typically have a plywood subfloor over the structural steel "frame" floor. Under the plywood is a rubber mat, and under the mat is bare steel. We pulled all the plywood panels (they're separate sections, not one piece — helpful) and found the rubber mat beneath in varying states of decomposition. The mat had been sealing moisture against the steel for decades in some areas.
When we pulled the rubber mat sections — that's where the surprises started.
What We Found Under the Floor
Front Third: Clean
The front 12 feet of the bus had minimal rust — surface rust only, easily treated. The school district replaced the front floor section about 8 years ago based on the records.
Middle Third: Moderate
Active rust on about 40% of the structural floor in this section. Deep pitting in several areas, but no perforations. Treatable with mechanical removal + POR-15. Estimated work: 2 full days.
Rear Third: Problem Area
The rear section near the emergency door had 6 perforations (holes through the structural floor) and 2 crossmembers with severe pitting. This requires welding before any other work can happen. Unplanned expense: called three mobile welders, got quotes of $480–$800 for patching the perforations and treating the crossmembers.
Emergency Door Seal and Skylight Inspection
The emergency door seal was deteriorated — this is the big rear door required by law on school buses. Replacement seal ordered ($68 from a bus parts supplier). The 5 factory roof hatches (skylights) were all intact and operational — a relief, since replacing these is expensive. Two had slightly degraded rubber gaskets that we'll reseal with butyl tape before insulation.
Interior Teardown Complete
Removed all remaining interior panels, overhead grab rails, driver's partition, emergency equipment mounts, and the first aid cabinet. The inside is now completely bare — bare steel walls, bare steel ceiling bows, bare (problem) floor. This is where it starts to feel real.
Standing in 280 square feet of empty metal space is both terrifying and exciting. It smells like 27 years of school bus. That smell goes away eventually, we're told.
Budget After Week 1
| Item | Cost |
|---|---|
| Bus purchase (GovPlanet) | $7,200 |
| Buyer's fee | $200 |
| Transport (flatbed) | $180 |
| State re-titling + registration | $135 |
| PB Blaster (seat bolt penetrant) | $18 |
| Impact socket set (for seat removal) | $44 |
| Emergency door seal (ordered) | $68 |
| Welding quote (not yet paid) | ~$620 |
| Seat sales (offset) | -$900 |
| Week 1 Running Total | $7,565 |
Lessons Learned in Week 1
- Inspect MORE floor than you think — We pulled 4 sections before buying. We should have pulled 10. The worst rust was in the rear, which we didn't fully inspect before purchase.
- Budget 30–50% more for structural work than you estimate — Our "small rust" budget was $400. Real cost will be $600+.
- Sell the seats immediately — Facebook Marketplace demand for bus seats is surprisingly good. List them the day you pull them.
- The smell is temporary — Allegedly.