[WIP] 2003 New Flyer D60HF Metro Transit Bus

[JLiu15]

UPDATE 8/15/25

The model is now completely built, after just over a year of work. All that's left to do is to make the custom stickers. The model contains over 6650 pieces, making this my largest MOC to date.

Since the previous update, I had to modify some of the roof as the roof AC units did not need such a large gap. Thanks to this piece recently becoming available in white, I was able to capture the sloped edge around the AC units while maintaining a smooth upper surface without studs. Acquiring them was a challenge given how new they are, and I ended up buying all the available ones from the only Bricklink seller to have them at this point. Even then, I had to buy a Lego City 60465 set (the only set it's available in so far) to have enough of them. I'm overall satisfied with how the roof AC units turned out given the availability of LEGO pieces.

The final part left to build after this was the bellows, which are designed identically in principle to the bellows on my New Flyer XD60 model. Because the real bus has 4 seats in the central section of the articulation joint (two on each side), I was initially concerned whether that could affect the bellows, but in the end the bellows still worked well and the central section with seats did not affect the bellows at all. Thanks to the space below the "floor" of the central section, I was able to stabilize the bellows with rubber bands below it. In the end, the model is pretty heavy and the rear section can sag a little at the articulation joint, but the bellows still seemed to handle just fine when I tested it driving and turning.

Overall, I am satisfied with how this model turned out. It is my fourth bus model, and I have definitely come a long ways since my first bus model (the New Flyer XD60). In fact, it has nearly 1500 pieces more than that model. On this model, I was able to include a full interior as opposed to a mere skeletal structure below the seats. The pneumatic doors also open and close much more similarly to a real bus. And with two PF XL motors used for propulsion, the model is able to move at a reasonable speed without the drive motors do not struggle with the weight of the model.

The photos and video for this MOC will be coming soon. I will also be publishing instructions for it on my Rebrickable.

Photos:

[Jerry LEGO Creations]

Very clean! I like the way you managed to integrate the battery pack

[JLiu15]

On 8/16/2025 at 9:52 AM, Jerry LEGO Creations said:

Very clean! I like the way you managed to integrate the battery pack

Thanks! Being able to press the power button and allowing it to be accessible for recharging plus keeping it concealed was definitely a challenge, but in the end the 2L thin liftarm for the power switch on the rear is the only thing that's exposed on the exterior for the entire setup.