Your AeroWorks Build Path

Every customer is different — so we built a process flexible enough for builders, families, full-timers, and DIYers. Whether you want a simple, insurable Base Coach or a full interior build, AeroWorks guides you through every stage with engineered quality and transparent communication.

Step 1 — Choose How You Want to Start

AeroWorks gives you two pathways to begin your build depending on your situation and your budget.
You can bring us a chassis you already own, or we can locate a suitable donor bus on your behalf.
Both paths lead to a safe, insurable, professionally-manufactured AeroWorks motor coach.

Option A — Bring Your Own Bus

If you’ve already sourced a bus, bring it to us. We perform a structural and mechanical suitability check to confirm it’s safe for conversion. Once approved, you secure your spot with a deposit and we begin the conversion process.

You remain responsible for the mechanical condition of your chassis.
We guarantee the work we perform — nothing more, nothing less.

Option B — We Help You Find a Bus

If you’d rather not hunt for a donor vehicle, we can assist. You set the budget; we locate candidates, inspect them, and help you choose a suitable chassis. Once you approve the vehicle, it is purchased on your behalf and delivered to our facility for conversion.

AeroWorks does not sell used vehicles or provide mechanical warranties.
We simply help you find the right platform.

Step 2 — Structural Conversion & Engineering

Once your bus is in the shop and approved, we move into the engineering phase:

Roof raise and transition sections

Framing and structural reinforcement

Window revisions

Rust remediation (if approved)

Exterior preparation for RV classification

This is where your bus stops being a school bus and becomes a motor coach.

Step 3 — AeroWorks Base Coach™ Installation

Every build begins with our Base Coach system — the minimum required for legal RV classification and insurance.

Included Systems:

Sleeping platform

Galley module with countertop, sink, pump, plumbing, and tanks

Fresh and grey water storage

12V electrical system (battery, fuse panel, lighting)

Shore power hookup

Smoke/CO safety systems

All systems are engineered to be permanent for inspection and modular for customer customization.

Step 4 — Choose Your Interior Path

Option A — DIY-Friendly Shell + Base Coach

The most popular choice.
You receive a fully engineered roof raise, Base Coach modules, and an open interior ready for your own creativity.

You get an insurable RV and a blank canvas.

Option B — Modular Interior Packages

Add modular components now or in the future. These bolt to reinforced anchor points and connect to the Base Coach systems.

Available Modules:

Bathroom module

Shower module

Extended galley

Cabinet systems

Power upgrade (inverter, solar, batteries)

HVAC options

Furniture modules (benches, dinettes, beds)

Option C — Full Custom Interior

For customers who want a complete, premium interior, we offer full turn-key builds with cabinetry, seating, bathrooms, power systems, and custom layouts.

Step 5 — VIN, Title & Documentation

Once your build meets motorhome requirements, AeroWorks assigns:

You Receive:

A brand-new AeroWorks VIN

Manufacturer documentation

RV classification

Weight ratings and safety details

A complete system walkthrough

This allows for insurance, financing, registration, and long-term resale value.

Step 6 — Delivery Day

Your AeroWorks Motor Coach is complete. You receive your documentation packet, system orientations, and options for future modular upgrades.

You now own a new AeroWorks Motor Coach, not an old school bus.