RFW Overlander: The ultimate expedition vehicle?

By Unsealed 4X4 9 Min Read
This fully restored off-grid overlander proves anyone can follow their passions – wheelchair and all
Words and Images by Harry Temple

THE OWNER
Picture this. You’re 20 years old and living life, pursuing your thirst for modifying, restoring and converting vehicles when the doctor taps you on the shoulder and before you know it, you’re in a wheelchair. As you are about to find out, Bill doesn’t let anything get in his way. Paralyzed from the waist down, Bill’s spinal tumor may have limited his mobility, but it ignited his passion. “I had the urge to keep moving forward,” Bill says, “because it’s not about what you can’t do, it’s about what you can do.” Fast forward 30 years and his company PME Auto Conversions are at the forefront of innovative vehicular modification and engineering solutions for people with physical challenges and disabilities, helping them regain their independence. He passed down his passion for the outdoors to his two children and toured in a basic camper trailer set-up while they were young, but it wasn’t a straightforward process. It wasn’t until they ran into a tricked out Toyota Coaster cresting a dune at Stockton Beach that the idea for a larger, expedition-style vehicle started forming in his head.

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THE VEHICLE
He soon realised the Coaster would be too small, and other popular expedition vehicle choices like a Unimog, M.A.N or Isuzu all required too much work and importantly, the floor wasn’t level. He stumbled across the RFW on Bus Sales eight years ago, and true to the car buying cliché, the picture was better than the product. Bill reminisced, “My brother told me not to do it … that I was mad”. It was one of two custom-made RFW (Robert Frederick Whitehead) buses built in the early ‘90s, ‘Australian Adventurer One’ and ‘Two’, respectively. Vehicle two was reclaimed by the earth on Fraser Island and this one wasn’t far behind it. It began as a 28-seat 4X4 tour bus on the Central Coast, and then turned up ferrying tourists through the Pinnacles in WA. Even landing in the lap of backpackers (YIKES) it surfaced with a resto-nut who realised he had bitten off more than he could chew.

After shipping it home, Bill knew it wasn’t going to be an easy fix. But what he found after a month of grinders, oxy torches and skip bins was a complete lack of structural integrity. Full of bog, newspaper and once stripped back, it resembled the Sigma wreck on Stockton Beach. Disheartened, he nearly cut his losses. Pushing on, the six-year build commenced and it was stripped back to a skeleton, re-framed, re-skinned and received a remanufactured rear chassis. Bill still recalls nightmares about the rust, which turned into OCD, buying every tin of cavity wax within a 10km radius and coating every bolt under the bus. Everything you see on the bus was born, designed and brought to life in-house, by Bill and his team. From CAD renders through to fabrication and paint, he is full of praise for his hand-picked staff that helped make his dream a reality. Combining the inspiration from both European expedition builds and the Dakar/Middle-Eastern look was challenging, but worthwhile.

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Bill says some people get quite a shock when the lift descends after pulling up on the beach!

EXTERIOR MODS
Weighing in at 12-tonne unloaded, the RFW cuts an imposing figure. Not interested in chasing future engine gremlins, the mechanically injected 8.3-litre 220HP (164kW) 6CT V8 Cummins was rebuilt, adorned with a twin alternator set-up and gifted with an industrial-sized cooling system. The robust four-speed mechanical Allison auto was a determining factor in the purchase, as was the renowned RFW transfer case. The gargantuan Spicer diffs weigh the same as a 4-cylinder motor and both can be locked at the flick of a switch. “What’s countering gravity?” I hear you ask. The airbag suspension was overhauled with new bags, towers and cross members. Custom-made control arms and panhards work with bigger bump stops and Volvo truck shocks to keep the bus right side up.

The giant 45-inch Michelin tyres weigh 150kg each on the Spider rim set-up, adding additional un-sprung weight and maintaining a surprisingly impressive ramp over angle. Vehicle approach and departure are improved thanks to custom laser cut front and rear bars that are designed to follow the contours and surround the 18,000lb winch mount and 160-litre fresh water tank mounted behind the front and mask the engine compartment in the rear. A giant ADR35 air brake system and recently added exhaust brake ensure the bus doesn’t turn a Yaris into a pancake.

The Dakar-esque external cage was built to hold the spare wheel, some extra jerry cans and additional gear on the roof. 200W of solar feeds two RemTEC AGM batteries for a stonking 500Ah of power. Alternator belt squeal is a thing of the past, thanks to the 3KvA generator and 100Ah charge capacity of the 3000W Enerdrive inverter charger. Couple that with 270 litres of fuel on-board, and you don’t have to give the tank or batteries a drink for several weeks.

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‘Decrapitated’ is the word of choice here!

INTERIOR MODS
You can bet the quality continues inside. The Morris Minor front seats were hoiked in favour of back-saving air seats. The custom-made aluminium dash has more gauges, lights and levers than the space shuttle and you’ll never overheat as the substantial air con system overhead directs the air straight down your neck. If you thought the floor was timber, you weren’t alone. It’s actually a high quality scratch resistant, wheelchair friendly timber vinyl that shapes perfectly around the thoughtful mechanical access hatches in the floor. The oven and grill are hooked to external gas bottles, and the kitchen has everything from an upright Waeco to a kitchen sink and everything in between.

The cupboards and benchtops are teak, and there is an affinity for stainless steel marine latches everywhere you look. There is not a smidgen of wasted space internally. Forget wandering out of camp at night when nature calls. The vacuum-operated aeroplane-style toilet fits alongside the adjustable shower and ceramic basin. Don’t forget he squeezed in a washing machine as well! Just when you thought he couldn’t possibly fit anything else, there is the full-size queen bed and second TV just in case you have a programming clash. And that’s not all! Keep an eye out for PART 2 and a detailed breakdown of the interior fit-out and future plans in an upcoming issue of RV Daily Magazine.

Room to swing several cats … or a kangaroo

FINAL THOUGHTS
With a few little things to finish off, Bill is still fine tuning the set-up for his first big trip. A true passion for exploring the outdoors shines through and he takes great pride in his creation as well as answering the questions that come from nearly every 4WDer that he passes on the road. He is full of praise for his dedicated staff who made the whole build possible. Time to start making memories, mate!

The Cummins powerhouse, complete with twin alternators

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