Gary Bussy
A platform for testing DIY off-grid automation hardware. Also my house.
Summary
Gary Bussy is the converted shorty school bus I live and work out of. I purchased her in July of 2020 and it has been an evolving project over the years and has many years of plans to go. I've used it as a platform to learn more about lithium batteries, solar, and DIY home automation with Home Assistant.
I'm working on a whole separate wiki to track and document projects. I will link it here when it's ready. Below is a summary of various aspects of the build.
Specs
1995 Chevy Van G30 Cutaway Chassis
6.5L Detroit Diesel (NA)
4L80E Automatic Transmission
30 Gallon Diesel Tank
10,000lbs GVWR
1450 W Solar
4.5Kwh Lithium NMC 7s @ 25.2v Nominal
1kw+ AC Shore Charging + 3500w inverter generator
3000w Inverter
Induction Cooktop
Kettle
Microwave / Air-Fryer
Window AC that is probably dying (400w/5000btu)
Home Assistant OS on N5105 mini PC
Surveillance Cameras + Frigate + Google Coral
Driver's display
Remote Access
Security Notifications
Solar Generation & Usage Monitoring
Lighting, Fans, Appliance, etc Control
Most loads are on DC side and switchable
Services
The following are service I use in my bus for various things and I have provided referral links to help me maintain them.
Calyx Institute 4G/5G Internet
Calyx Institute is a non-profit doing security research and implementation for public use. A recurring membership fee includes a hotspot device that includes unlimited 4G or 5G data depending on membership level. As of writing I pay $150 quarterly for 4G service I started in 2020, though I could switch to a $400 yearly membership to reduce my monthly cost from $50 to ~$33. There are higher memberships which give you 5G service and more capable hotspot devices.
My referral link will give you and I both a free month upon your purchase:
https://members.calyxinstitute.org/r/gznkq
Future
I have a lot of plans for my bus but it will take time and money to complete. Many projects may be still in development or are simply dreams.
Push towards 2kw of solar - Far future goal, but existing solar is not enough for about 5 months of the year in Berkeley, CA.
10Kwh+ of lithium battery storage with a switch from Li-Ion to LiFePo4
High power alternator installed but needs proper DC to DC charging system from 12v to 24v
Finalize paint job with same blue as currently on front-end - accent rub bars and ports with black bed liner.
Replace hatch cover with tinted polycarbonate and custom opening mechanism (in development)
Proper freshwater storage and grey water capture system
Upgrade from swappable 6 gallon water jerry cans to undermount tank system with hose and gravity fill. ~10-30 gallons dependent on space.
Recirculating shower with tankless water heater.
Uses a set of filters to purify shower water so it can be recycled over several showers before being discarded and filters cleaned or replaced.
Only about 5-10 gallons of water for several showers. Actual count TBD, but existing research says up to 20 showers before replenishing shower water.
Leaning towards using propane for tankless water heater, but electric would force me to upgrade aspects of my electrical system (more batteries, solar, generator)
Every aspect of the bus should be available in Home Assistant, including main drivetrain information and control.
Custom ECU for mostly mechanical diesel engine and 4 speed transmission - control should be simple enough to be ran on a modern ESP32
Custom dashboard and gauges with CarPlay and Home Assistant access for monitoring during long trips.
A current project of mine focuses on the creation of custom expandable switch panels which would be great for commonly used functions allowing less use of a touch screen whilst driving.
Existing items still not available in HA
Generator start/stop and information tracking
DC chest fridge management
Tank statuses and warning automations
Motorized rear access ramp for motorcycles and other large item loading - WIP but haven't touched in years due to selling my motorcycle.
Initially I reinforced the wheelchair lift door into a ramp by reinforcing the steel structure and putting the side hinges on the bottom. My bus did not come with the lift. I used a winch and some pulleys to open and close it, but it is a poor solution requiring manual intervention for it to open and close.
A future version will swap the original door with a custom aluminum structure wrapped in aluminum diamond plate. A common garage door tension spring with cables will improve the lifting of the ramp, keeping it closed with electronic solenoid latches. It could be fully automated with a heavy duty stepper motor and various sensors.
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