For years my wife Bev and I had been talking about buying a special-purpose motorhome to accommodate Bev's various health challenges. I dislike towing anything, so a caravan was out of the question. Prior to this, any driving holiday we took usually involved travelling in our car and staying in motels. We were virtually living out of suitcases and hating it!

Back in 2010, finding disability-friendly motels was a real mission. In our opinion, travelling with our very own Bev-friendly suite – already set up 24/7 – had to be the way to go. However, we couldn't find a factory-built motorhome that would suit our needs. So we started looking for a suitable vehicle that could be modified.

How It All Started 

It was on a road trip along the Great Ocean Road as I flicked through a magazine one night, that I saw a Mercedes Vario bus for sale. Because it was a purpose-built special needs school bus that was only used every now and then, it was in near-new condition with very low kilometres on the clock. We fell in love with it straight away and arranged to meet the Sydney-based agent. We drove to Goulburn, paid for it; and drove it back to our home in Redland Bay, Queensland. And there it sat – in my shed – for the next five years while I struggled to find the time away from my automotive engineering business to make a start on the project. 

The only upside to the delay was that I was able to spend more time designing the motorhome for the extra strength it needed to handle what I was about to do to it. Here is a snapshot of the modifications undertaken: 

- Using 'nesting channels', I was able to double the strength of the chassis without changing the dimensions too much. The extra chassis strength allowed me to create two 3.5 metre long slide-out sections to create more space to cater for Bev's wheelchair and walker. One incorporates the toilet, shower, vanity and roll-out pantry; while the other houses the kitchen.

- Incorporating a remote-operated wheelchair lifter in the front stairwell.

- Installing Hendrickson four-link airbag suspension for a smooth ride, working with six levelling legs for easy campsite levelling.

- Raising the roof 30 centimetres and replacing the engine-powered coach air with two electric airconditioners.

- Installing four solar panels, a TV antenna and two remote awnings.

- Making provision for a lightweight on-board Suzuki Vitara, stowed inside the bus via the remote-actuated tailgate ramp. Once the car is out, the ramp can be raised to form a rear patio. The two single beds also hinge up and down to accommodate the car during transit; as do the two wardrobes, washer and dryer.

- Fitting four new AGM batteries and an extra air compressor in an easy-to-access outside drawer. There is also an emergency generator in the engine bay.

- Installing five under-floor 150-litre custom-made stainless steel tanks for water (grey and fresh) and diesel.

The Sign Off

I'm an automotive engineer, and every modification I made was carried out in compliance with Australian Design Rules, the Heavy Vehicle Registration Assessment Scheme, and every other engineering rule book. An independent engineer officially signed off on the build in 2021, some 11 years after we bought the bus.

Thanks to my crook left shoulder, I've since replaced the manual gearbox with an automatic transmission and mounted the T-bar shifter to the right of the driver. This opened up much more space between the front seats.

The exterior has a vibrant colour scheme. I used blues and turquoise to depict the sky and ocean, and a red kangaroo reflects the Red Centre. The silver around the bottom represents our 'girt by sea' sandy beaches. 

During this motorhome build there were many people who gave us support, providing everything from physical help and discounts to words of wisdom. We give you a very big THANK YOU.

A New Era

Unfortunately, after all that has been done to make this vehicle the very best home away from home a person could ask for, we are going to have to sell it. Due to health concerns, Bev and I have totally lost the drive to drive. Don't get me wrong, I love road trips and love driving, but we just don't have the confidence to travel too far from home.

I didn't think I would ever feel this way, but here we are. The truth of the matter is that I should have finished the project soon after I started it. I was warned by many people during the build not to be so fastidious and to just 'get in and go while you still can'.

And now our pride and joy is looking for another forever home. We hope she brings many happy memories to another couple who can take her to all the places we couldn't.

Category: Features
Written: Sat 01 Nov 2025
Printed: November, 2025
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