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UNIT-I:
Classification of Coachwork:

Styling forms, coach and bus body style, layout of cars, buses and
coach with different seating and loading capacity, types of
commercial vehicles, vans and pickups, etc. Terms used in body
building construction, angle of approach, Angle of departure, ground
clearance, Cross bearers, floor longitudes, posts, seat rail, waist rail,
cant rail, Roof stick, Roof longitude, Rub rail, skirt rail, truss panel,
wheel arch structure, wheel arch, post diagonals, gussets

Styling Forms: Types of Car Bodies

1. Microcar
2. Hatchback
3. Liftback
4. Saloon / sedan
5. Estate car / station wagon
6. Sports car
7. Convertible
8. Off-roader
9. Sport utility vehicle
10. Multi - purpose vehicle / minivan
11. Van
12. Camper / campervan
13. Pick up
14. Limosuine
15. Coupe

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1. Micro Car: These vehicles have engines under

1.0 litre, and typically seats for only two
passengers

2. Hatchback: A hatchback is a type of car which

has a sloped back and a rear door that swings
upwards when opened. Hatchbacks have a
shared passenger and cargo area

3. Liftback: A liftback is marketing term for a

hatchback, where opening area is more
sloped and longer and is lifted up to open,
offering more luggage space

4. Saloon car (BrE) / sedan (AmE) is a passenger

car with separate compartments for engine,
passenger and cargo. It is one of the most
common car body styles, It has fixed roof that
is full height upto the rear window.

5. Estate car — or estate (BrE) / Station wagon

(AmE) is an automobile with its roof extended
rearward over a shared passenger/cargo area
with access at the back via a third or fifth door
Station wagons can change their interior by
folding-down rear seats

6. Sport cars are designed to look and feel

"sporty", offering the motorist more
connection with the driving experience, while
providing the comfort of luxury vehicles. It has
usually 2 seats with two door designed for
performance at high speeds.

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7. Convertible: These models are provided with wind

up windows and folding roof. Also known as a
cabriolet or roadster

8. Off— road vehicles, or "off-roaders" are sometimes

referred to as an overland or adventure vehicle, is
considered to be any type of vehicle which is
capable of driving on and
off paved or gravel surface. It is generally
characterized by having large tires with deep, open
treads, a flexible suspension, or even caterpillar
tracks

9. Sport Utility Vehicle(SUV): Sport utility vehicles are

off-road vehicles with fourwheel drive and off-road
capability. SUVs, use a body-on-frame design. That
means the frame and body are built separately and
joined together during the manufacturing process.
These truck-based vehicles are generally more
rugged and can be used to haul larger payloads

10. Multipurpose (MPV) (BrE) / Minivan (AmE) is

a type of van designed for personal use.
Minivans are typically either two-box or one
box designs for maximum interior volume. It
has rear side windows.

11. Van, camper , RV, minibus: A van is a kind of

vehicle used for transporting goods or people.
Depending on the type of van, it can be bigger
or smaller than a pickup truck and SUV, and
bigger than a common car

12. A campervan/camper/caravanette, is a
vehicle that provides both transport and
sleeping accommodation

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13. A pickup / pick-up / pickup truck is a light

motor vehicle with an open-top, rear cargo
area (bed) for transportation of goods

14. Limousine It is a luxury car. They are longer

than regular cars. The front and
rear wheels are far apart. A limousine may
have security features such as bulletproof
glass. It is usually provided with a partition
between the driver and the passengers.
Cushioned seats, air conditioning cooling
glasses etc. are the other features of this
model.

15. Coupe: A Coupe is car which are often sporty

variants of saloon or hatchback styles, with
doors generally reduced from 4 to 2 and a
close –coupled interior.

Coach and Bus Body Style:

Coach with different Seating and Loading Capacity

Passenger carrying buses are classifies based on:

1)Distance traveled by the vehicle

2)Capacity of the vehicle
3)Shape and Style of the vehicle

1.Distance traveled by the vehicle:

1.Mini bus
2.Town bus
3.Suburban bus
4.Long Distance Coaches
5.Touring Coaches
6.Midi bus

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Mini Bus Town Bus or City Bus

•It should have a seating capacity upto • It is for short distance journeys of about 30
25. km.
•It built on light duty truck chassis. • It has large standing space.
•It has front mounted engine and rear • It has relatively hard seating, covered with
axle drive. durable trim materials such as PVC etc.
•It has soft and comfort suspension. • Due to short intervals between stops in
•It has reasonably comfortable seat. local traffic, wide entrance and exit are
•It has fairly small entry platforms. provided with low steps entry and exit
platforms.

Suburban Bus Long Distances Bus

• These buses are used for a distance • These buses are used for a
of about 40 to 50 kms. They usually distance of about 200 kms and
have reasonably comfortable seats. above.
•Fairly small entry platform for the extra •They have comfortable seats
space can be used for luggage and with under floor luggage space
extra standing passengers. and roof racks for large items
•Usually one door is sufficient for this of luggage.
type of operation.

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Touring Coaches Midi Bus

• For longer distance touring coaches, very •A midibus is a classification of
comfortable reclining seats are used. single-decker minibuses which
•Toilets, air conditioners, TV,etc are are generally larger than a
provided. traditional minibus but smaller
•Additional windows in the roof are used to than a full-size single decker
improve visibility for the passengers. and can be anywhere between
• Thermal and acoustic insulation is 8 metres and 11 metres long.
usually elaborate and spacious luggage
compartments are provided under the
floor and on the roof

2.Based on the capacity of the vehicle

S. Type of Bus Passenger Capacity

No.
1 Mini Bus 15-26
2 Small coaches for long distances 16-30
3 Small buses for town Upto 40
4 Medium coach for long distance 31-45
5 Medium buses for town 41-60
6 Large coaches for long distances 46-60
7 Large bus for town 61-80
8 Large articulated buses 80

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3.Based on Shape and Style of the vehicle

1. Classic type 1.Classic type
2. Single Decker This type of bus has the engine in front of the
3. Double Decker passenger carrying compartment.
4. Split‐level bus This has less space because the front part is
5. Two‐level single Decker stretched out.
6. Articulated bus This also has poor aero dynamical design which
decreases the fuel economy. So, these types of buses
are not in use now a day.
The angle of vision is low because of longer front
part.

Single Decker Bus

1. The single deck bus is almost universal today as this layout eliminates all the
disadvantages of above type.
2. Single-decker is a bus that has a single level. Normally the use of the term
single-decker refers to a standard 2 axled rigid bus.
3. In this type of buses engine is mounted either inside or below the driver’s cab
enabling additional length available for more seats and a better angle of
vision.
4. These have two doors for shorter distance travel and have only one door for
longer distance of travel.
5. Many single deck models have seating capacity of fifty two which in city buses
is reduced to have more space for standing. This enables transportation of
more passengers for short duration.
6. It has a better angle of vision than normal control type.
7. It has roof rack for hand luggage.

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Double Decker Bus

• These buses have rear mounted engine which affords a front entry or good
forward visibility for passengers
• Such buses have passenger capacity of approximately sixty five to seventy
five. It may have upper deck open for tourists.
• Double decker buses have poor stability than single decker buses
• These are used in metropolitan cities.

Split Level
1. An intermediate solution between the
two is the split‐level layout.This layout
has more seats than a single Decker
and more stability than the double
Decker.
2. However, owing to the small number
of variations that can be made from
this basic design, it has not been
widely accepted.

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Two Level Single Decker

1. This type of buses is used as luxury coaches.
2. The layout provides good forward visibility for all passengers and good
separate luggage space under floor
3. Good luggage space and easy installation of an under floor or rear engine.
4. The driver compartment is separated from the passenger’s compartment.
5. This type is only made for special orders as it is not easy to make
derivations from the same body shell.

Articulated Bus
1. Articulated Vehicle/Bus’ means a vehicle which consists of two or more rigid
sections which articulate relative to each other;
2. the passenger compartments of each section is interconnected by an articulate
section allowing free movement of passengers between them;
3. the rigid sections are permanently connected and can only be separated by an
operation involving facilities which are normally found in a work shop.
4. Bodies for very large coaches or in particular city buses are often made in two
parts because of axial load limitations. Articulated buses are buses of a type with
an increased passenger capacity. Found almost exclusively in public
transportation use. These buses are approximately 18 m (60 ft) long, while
regular buses are 11 to 14 m (35-45 ft) long.
5. This type of bus is also known as Accordion bus, Harmonica bus, Jointed bus, or
Bendy bus, all because of the shape of the bellow and the fact that the design of
the turn table joint allows for sharp turns.

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Car Layout
The engine may be placed in different positions within the vehicle , each
having its own advantages. There are following engine configurations

There are four different types of drivetrains:

• all-wheel drive,
• four-wheel drive,
• front-wheel drive,
• and rear-wheel drive.

FRONT ENGINE –FRONT WHEEL DRIVE

• In this type of chassis layout the engine is fitted at front and drive
is also given to the front wheel .No propeller shaft is used in this
layout and differential are included in the same assembly.
• The engine weight over the driven wheels gives greater traction.
• This layout provides optimum body luggage space and flat floor
line .However , due to all assemblies at front ,it make very
difficult to accommodate the steering mechanism.

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FRONT ENGINE – REAR WHEEL DRIVE

• In this chassis layout ,the engine is fitted at the front.
• The engine ,clutch and gear box are fitted at front while drive to
the rear axle is given with the help of propeller shaft
• This chassis layout is one of the oldest and still remain popular for
heavy commercial vehicle.

REAR ENGINE-REAR WHEEL DRIVE

• In this chassis layout engine is fitted at the back and drive is also
given to rear wheel

ADVANTAGES
• This arrangement eliminate the necessity for a propeller shaft
because engine is mounted near the driven wheel.
• The passenger are kept away from inconveniences like noise,
heat and fumes because engine at back of vehicle

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4 WHEEL DRIVE
• A transmission system which provides power directly to all four wheels of
a vehicle. A vehicle with four-wheel drive, typically designed for off-road
driving. Four-wheel drive, also called 4×4 or 4WD, refers to a two-axled
vehicle drive train capable of providing torque to all of its wheels
simultaneously.
• It may be full-time or on-demand, and is typically linked via a transfer
case providing an additional output drive-shaft and, in many instances,
• E.g. are Jeeps, SUVs(Sports Utility Vehicle), etc.

All-wheel drive (AWD)

• A transmission system that always operates in four-wheel drive and
does not alternate with two-wheel drive.
• All-wheel drive (AWD) is a drive train configuration engineered to direct
power to all four wheels of a car simultaneously.
• All-wheel drive (AWD) train system includes a differential between the
front and rear drive shafts.

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Types of Commercial Vehicles, Vans and Pickups, etc.

Commercial vehicles are divided into 8 classes based upon the gross vehicle
weight (GVW).

Light Medium
Weight Class Light Duty Light Duty Medium Duty Medium Duty Heavy Duty
Duty

Class 1 Class 2 Class 3 Class 4 Class 5 Class 6 Class 7 Class 8

From (lbs.): -- 6,001 10,001 14,001 16,001 19,501 26,001 33,001

To (lbs): 6,000 10,000 14,000 16,000 19,500 26,000 33,000 --

LIGHT DUTY: GVW classes 3-4. Includes, trucks, buses, and recreational
vehicles.
LIGHT MEDIUM: GVW class 5 – some are light, some are medium. Includes
trucks, shuttle buses, and RVs
MEDIUM DUTY (MD): GVW classes 6-7. All fuel types and applications
including class 6-7 school buses.
HEAVY DUTY or CLASS 8 VEHICLES: defined as a straight truck or tractor
over 33,001 lbs
MIDRANGE: Classes 3 – 7 vehicles. Refers to typical operation range of
vehicles, which is primarily of a local and regional nature

Types of Commercial Vehicles.

The commercial goods vehicle is used to identify a vehicle and the main reason
is to transport goods or materials rather than passengers. This commercial
vehicle will generally able to carry two, three or more passengers. However,
after the seating will be something designed to carry materials or tow something
large.

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Type of Small Commercial Goods vehicles :-

1.Panel van Small Commercial goods vehicle :-
This is the most common type of commercial vehicle
and many drivers favor its ability to carry a sizeable load
while also being easy to drive.

2.Double cabin van Small Commercial goods vehicle :-

This van is similar to a panel van but an extra row of
seats is fitted behind the front seats. The windows are
added next to these rear seats.

3.Pick-up truck Small Commercial goods vehicle :-

It may use them more often as family transport than for
moving cargo, pick-up trucks are classed as light
commercial vehicles. It is design similar to cars and feel
of the cabins is also tend to be made by the same
manufacturer, especially the improved offerings of
modern-day pick-up trucks.

4.Drop side van Small Commercial goods vehicle :-

It is a similar fashion to pick-up trucks and it has
large and open loading bays at the rear. This van is
generally based on existing commercial vehicles
and panel vans.

5.Tipper van Small Commercial goods vehicle :-

It is a similar design to dropside vans and being two
or three-seater vehicles with a large, open loading
bay. It has extra technology surely makes a tipper
van more costly than a drop side van. But, its
facilities make it a popular choice of vehicle for
those that want to transport the likes of rubbish or
gravel.

6.Chassis Cab Small Commercial goods vehicle :-

These cabs are stripped down to the bare basics
behind the one or two seat-row passenger cabin.
The chassis rails are found, as against to a pre-
assembled container or load area.

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Types of Commercial Trucks

When designated for business use, many vehicles qualify
as commercial vehicles as follows:
1.Semi-trucks. Semi-trucks are a combination of a tractor
unit attached to a trailer or bed using a fifth-wheel
connection. They are also called 18-wheelers, tractor-
trailers, and big rigs. Semi-trucks include dry vans, reefers,
double or triple trailers, and flatbeds. Semi-trucks are used
to haul cargo between distribution and fulfillment hubs.

2.Box trucks. Box trucks or straight trucks look like semi-

trucks, but their tractor is directly attached to the trailer
without a fifth-wheel connector. Unlike vans, box trucks
have their cargo area separate from the vehicle’s cab.
Businesses often use them for moving, local deliveries,
and hauling large items like furniture and appliances.

3.Pickup trucks. Most ordinary pickup trucks aren't

automatically considered commercial vehicles. However,
sometimes they're used for commercial purposes. Pickup
trucks can transport goods with a trailer and transport
tools and equipment for a business.

Types of Commercial Van

1.Step vans. Also called multi-stop or walk-in delivery, these
kinds of trucks are known as "bread trucks" or "bakery trucks"
colloquially. These vehicles are taller than full-sized vans,
making it easier to access goods and stand up in. Parcel
companies (including the United States Postal Service), police
and fire departments, and food trucks use delivery trucks.

2.Cargo vans. Cargo vans — also called sprinters — are one-

piece vehicles with their cargo area connected to the driver
cab. Some larger cargo vans have roll-up rear doors, similar to
box trucks. Cargo vans are typically used for plumbing,
electrical, cable repair services, and courier and delivery
services.

3.Passenger vans. Full-sized commercial passenger vans can

seat anywhere from nine to 15 passengers. They’re used to
transport groups of people as part of a service (transporting
guests to a parking lot) or as the service itself (travel or tour
operations).

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Types of Buses
1.Buses. Transit buses are designed to transport large
amounts of both paying and non-paying passengers. They
are typically part of a city’s transportation network or used
for school bus systems.

2.Motor coaches. A motor coach is a more luxurious bus

designed to travel long distances. Modern motor coaches
are high-floor buses, with luggage storage below the
passenger compartment. These passenger vehicles are
designed for comfort, with more amenities than regular
buses, such as air conditioning, onboard restroom, and
reclining seats.

3.Minibus. Also known as shuttle buses, these vehicles have

lower passenger capacities than regular buses but more
than passenger vans. Due to their smaller, more flexible
nature, minibuses are used for both fixed-route transit and
on-demand transportation.

Miscellaneous
Heavy equipment. Some types of construction, farming, mining equipment
and similar heavy vehicles are considered commercial vehicles.

Specialty vehicles. These vehicles have specific functions or designs. For

example, government agencies and communities rely on refuse collection,
street sweepers, fire trucks, and septic trucks. Tow trucks, passenger
trolleys, and RV-style mobile services (bookmobiles, health services) can all
be considered commercial vehicles.

Commercial cars. Rental cars, taxis, and delivery vehicles are all considered
commercial vehicles. While ride-hailing vehicles (Uber, Lyft) are still
considered personal use vehicles, many believe they should be considered
commercial vehicles with commercial plates.

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Terms used in Body Building Construction……

Approach angle It is defined as the angle between ground level and a line
drawn from the lowest part of the front of the vehicle, usually the front
bumper, to where the front tire touches the ground.
The approach angle of your vehicle will determine how steep of an obstacle
you can climb or descend, without your bumper or other portions of the
frame touching the obstacle or the ground.
Departure angle The departure angle is defined as the angle between
ground level and a line drawn from the rear of the back tire to the lowest
point on the car’s rear.
The departure angle of your vehicle will determine how steep of an angle
your car will be able to climb so that your rear bumper doesn’t hit the
ground as your back tires climb onto a slope

Terms used in Body Building Construction……

Breakover Angle: It angle is the maximum supplementary angle that the car can
travers such that when one set of wheels are on one side of the apex and the trailing
wheels on the other side of the apex, the apex of the peak does not touch the
underside of the vehicle.
Essentially, the breakover angle will determine how steep a peak the vehicle can
traverse without the peak damaging the underside of your car.

Ground Clearance: The ground-clearance is the distance from the ground to the
lowest point on the vehicle’s underside and doe not take angles or peaks into
account.
Ground-clearance only factors in flat ground and will affect the depth to which you
can drive through deep ruts or deep mud without scraping the vehicle’s underside.
Breakover angle takes the slopes on either side of the peak into account to make
sure the underside of your vehicle will clear the apex of the peak.

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Terms used in Body Building Construction….

Cross Bearers: These are transverse members of rolled mild steel channel, usually of
75x40 ISMC, that form the foundation for the body structure. More the number of
cross bearers better the distribution recommended between two cross bearers.
The number of intermediate cross bearers depends on the number of windows to be
provided.
Floor Longitudes: These are the longitudinal members inter connecting the
crossbearers and forming the floor structure. These are usually of 3mm thick pressed
MS channel and are arranged in five rows

Terms used in Body Building Construction…

Seat Rail: This is the longitudinal member running the entire, length of the side
structure to which the legs of the seats (on the window side) are bolted (the aisle side
legs are bolted on the floor longitude).
Cant rails: are structural members that connect two body sections above the window
section.
Waist Rails: are structural members that connect two body sections below the
window section.

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Terms used in Body Building Construction….

Posts (Pillars): These are upright members of press steel ‘hat-section’ forming the
side frame structure of the body and extended from the skirt rail level up to the
cant rail level.
Skirt Rail: These are the rolled MS angles running parallel to the west rail at the
skirt portion of the side structure.
Post Diagonals: These are the side frame members (Of MS angles) provided to
reinforce the structure in the wheel arch area and to prevent major structural
damages in case of any accidents.

Terms used in Body Building Construction…

Roof Stick: These are the main transverse member of the body structure
spanning the width of the roof interconnecting the post on either side
Roof Longitudes: These are the longitudinal members (made of press steel
‘hat’ section) running the entire length of the roof.
Rub Rail: This runs just above and parallel to the floor level on the side
structure. This is provided to fit a full length rubber beading along the side

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Terms used in Body Building Construction…

Truss panel: This is a MS sheet provided at the roof corners just above the door
openings to compensate for the weakened side frame structure in that area.
Wheel Arch Structure: These are provided on the side structure to allow for the
movement of the tires at turns and to support the wheel humps.
Wheel Hump (Wheel arch): This are the sheet pressings suitably contoured to
accommodate the tires and the form part of the floor assembly.

Terms used in Body Building Construction….

Anti-Drumming rails: These are the channel sections running along the side
structure in between the west rail and the seat rail. These members help in
reducing vibrational noise.
Gussets: The triangular box section fabricated out of MS plates help in
strengthening of Joints of longitudinal and transverse members.
A plate or bracket for strengthening an angle in framework (as in a building or
bridge)

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Terms used in Body Building Construction…..

1. Entrance doorway skirt panel
2. Skirt panel front of front N/S wheel arch
3. Skirt panel rear of front N/S wheel arch
4. N/S main side panel Bay1.
5. Air filter access cap.
6. N/S main side panel Bay2.
7. Skirt panel.
8. Spare wheel access flap.
9. N/S main side panel Bay3.
10. Skirt panel front of rear N/S wheel arch.
11. N/S main side panel Bay4.
12. Rear skirt panel, N/S.
13. N/S main side panel , Bay 5.
14. Pillar capping between Bay1 & entrance door.
15. Pillar capping main pillars.

Terms used in Body Building Construction…

16. Roof panel Bay1.
17. Roof panel Bay 2.
18. Roof panel Bay 3.
19. Roof panel Bay 4.
20. Valance panel for spare wheel access flap.
21. Valance panel.
22. Valance panel for air filter access flap
23. Front skirt panel O/S.
24. Main side panel below driver’s signaling window O/S.
25. O/S main side panel Bay 1.
26. Skirt panel rear of front O/S wheel arch.
27. O/S brake gear access flap.
28. Valance panel for O/S brake gear access flap.
29. Valance panel.
30. O/S main side panel Bay 2.

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Terms used in Body Building Construction…

31. Skirt panel front of rear O/S wheel arch.
32. O/S main side panel Bay 3.
33. O/S rear skirt panel.
34. O/S main side panel Bay 4.
35. Main side panel below emergency door.
36. Emergency door main side panel.
37. Pillar capping between emergency door and Bay 4.
38. Emergency door, top rail capping.
39. Emergency door, shut pillar capping.
40. Emergency door, hinge pillar capping.
41. Water bottle flap.
42. Fuel filter flap.
43. Header tank flap.
44. Electrical flap.
45. N/S rear pillar capping.
46. O/S No 1 pillar capping

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