The Art of Building a Bus

 

When you see a gleaming luxury bus gliding down the highway, what you’re actually witnessing is the result of weeks of skilled craftsmanship. At Shivam Coach Builders, we don’t just build buses — we create experiences. From a basic chassis to a fully functional, safe, and luxury vehicle, the journey involves engineering excellence, attention to detail, and a deep understanding of what passengers and transport operators need.

In this blog, we’ll walk you through the step-by-step process of bus body building, right here in Gujarat — the heart of India’s industrial strength.

 

1. What is Bus Body Building?

Bus body building is the process of designing and constructing the external and internal structure of a bus on top of a bare chassis. While manufacturers like Tata or Ashok Leyland provide the base chassis, the real transformation into a luxury, sleeper, or mini bus is carried out by specialized builders like Shivam Coach Builders.

We are luxury bus body fabricators in India, recognized for our high-quality work, innovative designs, and commitment to safety.

 

2. Starting Point: Receiving the Chassis

The journey begins when the bus chassis — the base frame with wheels and engine — arrives at our Ahmedabad workshop.

We commonly work on:

  • Tata chassis

  • Ashok Leyland chassis

  • Volvo chassis

  • Mini bus chassis

Our team first inspects the chassis for structural compatibility and then begins planning the bus body according to the client’s requirements — whether it's for a school bus, tourist bus, AC sleeper bus, or mini coach.

 

3. Bus Body Structure Design

Before welding or cutting begins, a 3D model of the bus body structure is created. Our designers use CAD tools to plan:

  • Dimensions

  • Passenger capacity

  • Storage space

  • Emergency exits

  • Seating layout

  • Air conditioning system integration

For us, design isn't just about appearance. It must be:

  • Aerodynamic

  • Structurally strong

  • Compliant with AIS-052 and CMVR standards

 

4. Fabrication: Frame Building

Once the design is approved, we start building the skeleton of the bus using mild steel or aluminum alloy.

Our bus body fabrication process includes:

  • Chassis mounting

  • Welding the main frame

  • Roof structure

  • Floor base installation

This stage is crucial for durability and safety. The frame is then coated with anti-rust paint for longevity.

 

5. Exterior Paneling and Roofing

Next comes the outer body — typically made with galvanized or aluminum sheets. These are fixed on the frame to form the walls, roof, and body shape. Insulation is added to the roof and walls to ensure climate control, especially in AC bus body building.

We offer various exterior styles:

  • Standard

  • Luxury Coach

  • Volvo-style

 

6. Interior Work: Where Comfort Begins

The real luxury lies inside. Our interior bus body work includes:

  • Flooring: Vinyl, laminated wood, or carpet

  • Ceiling Panels: With LED strip lighting

  • Windows: Tinted, sliding, or fixed glass

  • Seats: Recliner or sleeper, with armrests and charging points

  • Air Conditioning Ducts

  • Driver’s Cabin Design

For sleeper bus body builders, we include full-length berths with curtains, lighting, and USB ports.

 

7. Electrical & Safety Features

Every Shivam Coach bus includes top-notch safety and electrical features:

  • GPS system

  • Rear-view camera

  • Fire extinguishers

  • Emergency exits with alarms

  • ABS-compatible wiring

  • Night vision lights

 

8. Painting and Branding

After structural and interior work is done, the bus is painted using PU or automotive-grade paints. Clients can choose from:

  • Metallic finishes

  • Dual-tone designs

  • Company branding or logos

We also apply anti-scratch coating and reflective stickers for night safety.

 

9. Quality Inspection and Testing

Before delivery, each bus goes through multiple inspection stages:

  • Leak tests

  • Vibration tests

  • Electrical system test

  • Road performance check

Every vehicle we build passes a 40+ point checklist to ensure it meets India’s bus manufacturing standards.

 

10. Final Delivery and Client Handover

After testing, we prepare detailed documentation, registration support, and client briefing. The new luxury bus is now ready to hit the roads!

From school transport to intercity tourism, our buses are seen across Gujarat and beyond.

 

Why Choose Shivam Coach Builders?

✔ Experience: Over a decade in the industry
✔ Location: Based in Ahmedabad, Gujarat
✔ Customization: Tailored designs for every need
✔ Support: End-to-end support from chassis to road
✔ Repair Services: We also provide bus body repairing services for Tata, Ashok Leyland, Volvo, and more

Whether you're a travel company, educational institution, or corporate, we deliver buses that combine style, comfort, and safety.

 

If you’re planning to build a custom bus body in Gujarat, get in touch with us today.

📞 Contact: +91 9033033102
📍 Address: Near HP Petrol Pump, Nana Chiloda, Ahmedabad – 382330
🌐 Website: shivamcoachbuilders.com