In a moment when transit agencies are grappling with aging fleets, long vehicle procurement lead times, and constrained capital budgets, innovation doesn’t always come in the form of a shiny new bus. Sometimes it comes rebuilt on a chassis that has already logged thousands of miles. 

That’s precisely what happened at Washington State’s Everett Transit, where a partnership with Complete Coach Works (CCW) turned strategic refurbishment into a model of innovation worth celebrating.

Refurbishment Over Replacement

The traditional definition of transit innovation often centers around advanced technologies, zero-emission propulsion, or state-of-the-art manufacturing. 

But Everett Transit, facing a confluence of urgent operational needs, chose a different path rooted in practicality, sustainability, and long-term vision.

Rather than joining the queue for new bus deliveries delayed by global supply chain issues, Everett Transit partnered with CCW to breathe new life into its existing fleet. 

Through a comprehensive refurbishment program, aging buses were transformed into like-new assets ready to meet the demands of daily service.

Everett Transit’s decision to pursue refurbishment was driven by a trio of challenges shared by agencies across the country, including:

• Aging fleets that require more frequent and costly repairs.

• Capital limitations that constrain the ability to replace a large number of buses. 

• Severe procurement delays stemming from manufacturing backlogs and parts shortages.

The CCW refurbishment program directly addressed all three of these typical challenges. Each bus underwent a detailed assessment, followed by a tailored scope of work focused on safety, reliability, and rider comfort. 

A Tailored, Turnkey Approach

The CCW/Everett Transit collaboration wasn’t a one-size-fits-all retrofit, but rather a precision effort. 

Each vehicle’s condition and service expectations informed a custom refurbishment plan, which included mechanical overhauls to improve performance and reliability, structural restoration to extend the lifespan and enhance safety, interior upgrades for a more comfortable riding experience, and rebranding and exterior refinishing to match the agency's aesthetics.

Thanks to CCW’s vertically integrated capabilities, the entire process was executed efficiently and with minimal disruption to service, explains Mark Hollenbeck, business development manager at CCW.

“Together with Everett Transit, we developed a customized scope of work for every vehicle, prioritizing safety, mechanical reliability, and interior upgrades,” he explains. “This collaborative approach ensured that every refurbishment aligned with the agency’s service requirements, rider expectations, and budget goals.”

Everett Transit has reported significantly reduced maintenance costs, improved vehicle reliability comparable to that of new buses, enhanced rider satisfaction with better interiors and aesthetics, and increased operational resilience with fewer service interruptions.

Most importantly, the agency maintained consistent, uninterrupted service to the community during a time when many others were forced to scale back due to a lack of operable vehicles.

Sustainable and Replicable at its Core

In a transit environment increasingly focused on sustainability, CCW’s approach offered Everett Transit an alternative that could help the agency achieve its goals with less financial investment than new, modern buses would have required.  

Refurbishing a bus prevents thousands of pounds of raw material waste and reduces the carbon footprint associated with manufacturing and shipping new vehicles. 

For Everett Transit, this meant embracing not only operational and budgetary sustainability but also environmental stewardship.

“Refurbishment is a strategic tool for agencies struggling with aging fleets, limited budgets, or procurement delays. We encourage a mindset shift that instead of waiting for new buses, agencies can invest in the resources they already have,” says Hollenbeck. “It’s a scalable, replicable model that protects service continuity while advancing long-term fleet goals.”

By winning one of METRO’s Innovative Solutions Awards for Sustainability, this project underscores a crucial truth: in times of uncertainty, practical solutions often lead the way. 

Everett Transit’s embrace of refurbishment was not just a temporary fix, but rather an innovative approach to accomplish its goals.

“Everett Transit was thrilled to see this partnership recognized with an innovation award,” says Hollenbeck. “The agency viewed the refurbishment initiative not just as a necessary operational solution, but as a bold step toward rethinking how transit systems can maximize limited resources while still delivering high-quality service.”