How To Customize A New Bus?
You are not limited to what is on the lot. Chassis, engine, seating, storage, flooring, and ADA choices available when you order a bus built to spec.
By Bryan George
Published
This article was reviewed and updated on December 23, 2025.
Building the perfect bus for your needs
When the time comes to buy transportation for your organization, remember that you are not limited to what is sitting on the lot.
One of the greatest advantages of working with a dealer like Carpenter Bus Sales is the ability to customize new shuttle buses for sale.
By tailoring the vehicle to your specific situation, you ensure passenger comfort and operational efficiency. Customization options are vast, ranging from the mechanical chassis to the interior fabric.
This guide explores the most common ways our customers build their ideal bus.
1. Choosing the right chassis
The chassis is the foundation upon which the bus body is built. Roughly 80% of the time, commercial bus manufacturers utilize either a Ford™ E-Series or Chevrolet™ Express cutaway chassis.
However, the market has evolved. For smaller groups or more nimble handling, platforms like the Ram ProMaster™, transit vans, and the Mercedes-Benz™ Sprinter have gained significant popularity in the luxury and shuttle sectors.
2. Engine selection: Gas vs. Diesel
Your choice of engine should be determined by your annual mileage.
- Gasoline: Ideal for lower mileage use. It has a lower upfront cost and cheaper maintenance.
- Diesel: If you plan to put over 25,000 miles per year on your bus, the diesel option is generally better. It offers longevity and torque but typically comes with a $4,000 to $9,000 up-charge depending on the manufacturer.
- Alternative Fuels: Options like Propane (LPG), CNG (Compressed Natural Gas), or Hybrid systems are available for fleets with green initiatives. Be aware that these systems can add anywhere from $6,000 to $40,000 to the build cost.
3. Seating configurations
The number of passengers you carry dictates the floor plan, but the comfort level is up to you.
Featherweight seats are the industry standard, available in mid-back (standard support) or high-back (head support) styles.
For a more upscale feel, upgrading to Berkshire™ limo-style seating is highly recommended. Fabric choices range from durable cloth and anti-microbial vinyl to premium leather, allowing you to match your organization's aesthetic.
4. Luggage and storage solutions
If your bus will be used for airport transfers or multi-day trips, storage is non-negotiable.
Buses can be configured with:
- Overhead Storage: Similar to an airplane, perfect for backpacks and small bags.
- Rear Storage: A dedicated luggage wall or cargo net in the back of the bus (reduces seating capacity).
- Under-Bay Storage: Available on larger "medium-duty" buses, offering exterior compartments for heavy luggage.
5. Flooring options
Flooring sees the most wear and tear. The least expensive option is typically a basic black rubber floor, such as Gerflor™.
For superior durability and safety, we recommend Altro™ safety flooring. This medical-grade vinyl is slip-resistant and comes in a variety of wood-grain patterns and colors that hide dust and dirt better than standard rubber.
You can learn more about flooring safety standards at the Altro™ website.
6. ADA compliance
If you transport elderly passengers or individuals with disabilities, accessibility is key.
Buses can be custom-built with commercial wheelchair lifts (from BraunAbility or Ricon) and designated wheelchair securement stations. We can also configure storage racks specifically for walkers to keep aisles clear.
For guidelines on accessibility requirements, visit ADA.gov.
7. Graphics and exterior branding
Don't miss the opportunity to turn your vehicle into a mobile billboard.
With modern digital printing, the sky is the limit. You can choose simple vinyl lettering for your church name or a full-vehicle wrap that showcases your brand colors and logo.
Customizing a new bus is the best way to ensure your investment serves your specific group effectively. With endless possibilities, Carpenter Bus Sales is here to guide you through the process.
Browse our current inventory or call us today at 1-800-370-6180 to start your custom build.
Frequently Asked Questions
How long does it take to order a custom bus?
Lead times vary by manufacturer and season. Generally, a custom-ordered bus from manufacturers like Starcraft or Glaval can take anywhere from 90 to 120 days (or longer) to be built and delivered. We recommend planning well in advance.
Can I customize a bus I buy off the lot?
Yes, to an extent. We can add aftermarket upgrades to stock units, such as adding custom graphics, upgrading the audio/video system, or installing specific safety equipment like backup cameras. However, changing the seating layout or engine type requires a factory order.
Is leather seating worth the extra cost?
For executive shuttles or senior living facilities, yes. Leather (or high-quality faux leather) is easier to wipe down and sanitize than cloth, and it provides a more luxurious passenger experience.
Do you offer 4-wheel drive buses?
Yes, but they are specialized. We can order buses on chassis that offer 4WD or All-Wheel Drive (AWD), which is an excellent option for organizations in snowy climates or those traveling on unpaved roads.
Can I add a bathroom to a shuttle bus?
Yes. Larger shuttle buses (typically 25+ passengers) can be equipped with a rear restroom. Keep in mind that adding a restroom usually reduces the seating capacity by 2-4 seats.
About the Carpenter Bus Sales Editorial Team
This article was prepared and reviewed by the Carpenter Bus Sales Editorial Team, drawing on decades of experience serving church, school, and organizational transportation needs nationwide. Carpenter Bus Sales has specialized in bus sales and service since 1953.
Learn more at CarpenterBus.com.
