BODY ASSEMBLY SPECIFICATIONS

(a) Body assembly framing shall be electric mig welded and reinforced at all stress points. Body when assembled to the chassis shall be an integrated total assembly.

(b) All frame members shall be steel sections thoroughly high pressure cleaned and treated with epoxy primer.  

  (a) Floor framing shall be 14 gauge galvanized steel with formed C channel crossmembers on approximately 8 inch centers.

(b) Full body and passenger loads shall be transmitted to the main chassis rails through outrigger supports bolted to the web of the chassis rails with 1/2" Grade 8 bolts.

(c) Front and rear, and road and curbside walls shall be designed using rectangular tubing, Z and C channel steel as needed for proper structural strength.

(d) Roof framing shall be made of rectangular tubing, Z and C channel steel and formed into hat sections designed to transmit loads to the walls. Roof design shall depict the curvature and lantern designs of the 1800's streetcar. The lantern section roof shall have a minimum overhang of 4" on the front. Lantern type roof will be fabricated with fixed colored windows with steel basic framing insulated and covered with minimum .040 aluminum. A replica trolley pole to be fixed securely in a horizontal position is to be provided. No spring loading mechanism is to be provided.

(e) Body and understructure shall be of durable construction, adequately reinforced at all joints and points where stress concentration may occur so that vehicle will carry the required loads and properly withstand road shock.

(f) The underframe shall be stiff enough to prevent floor from flexing under normal loads. Material used in body and chassis shall be high quality, consistent with good body and chassis building practice.

(g) The side and end framing shall be so designed and constructed that they will carry their proportion of the stresses imposed and absorb excessive impacts with as little damage as is practical. Adequate reinforcements shall be installed around the side doors in order to transfer the stresses around these openings.

(h) Before assembly, all metal parts shall be treated with thorough multiple stage anti-corrosion treatment and primer painted.

(i) All nuts, bolts, clips, washers, clamps, rivets, and like parts shall be zinc or cadmium plated, or phosphate coated, to prevent corrosion. Where wood and wood are placed together, both shall be coated with Tuff-Cote, Neoprene, liquid polyurethane or other appropriate sealing compound.

(j) Body panels shall be minimum .063 inch thick aluminum or 18 gauge hot rolled steel.

(k) All posts in body side and roof sections shall be of durable channel or box construction securely fastened to the underframe structure so that the entire frame shall act as one unit without any movement at the joinings. The end posts shall be designed to resist shear. The body should be mounted on the frame with solid oak slats or hard rubber to absorb shock. All exterior panels shall be welded or riveted to body frame. No metal screws shall be permitted. Rivet spacing shall be in accordance with the best practice of bus industry standards. Exterior seams shall be constructed in such a manner that they will shed water, that is the leading panel shall be lapped over the following panel and in no case shall the sealing of the panels be dependent on caulking alone.

(l) All light fixtures on exterior shall be fastened with screws to frame members. Headlights must be supported by adequate frame support or reinforced body panels.

(m) The trolley shall resist corrosion from atmospheric conditions and road salts. It shall maintain structural integrity and nearly maintain appearance throughout its service life, provided it is maintained in accordance with the procedures specified in the service manual. Materials exposed to the elements and all joints and connections of dissimilar metals shall be corrosion-resistant and shall be protected from galvanic corrosion. Representative samples shall withstand a two week salt spray test in accordance with American Society for Testing and Materials Procedure B-117 with no visual or structural detrimental effects to normally visible surfaces, and no significant structural degradation or weight loss of over 1 percent for other members or components.

(n) Trolleys shall be undercoated with Lubrizol compound corrosion prevention, or approved equal.  

  (a) Front, if any, and rear wheelhousings shall be constructed of 16 gauge stainless steel, sound deadened and undersealed with minimum 1/8" thick undercoating to eliminate sound transmission into the interior.

(b) Front stepwell assemblies shall be constructed of stainless steel unless provided differently by the step lift manufacturer.  

(a) There shall be a 14 gauge galvanized steel floor with 2" formed C channel crossmembers on approximately 8" centers. The floor shall be secured with 3/8" Grade 8 flange head bolts.

(b) Plywood of 3/4" 5-ply minimum marine A-B grade with all joints and edges sealed prior to installation shall be installed on top of the steel floor.

(c) Plywood floor sections shall be secured to the galvanized steel floor using 1/4"-20 counter-sunk self tapping screws.

(d) Entire floor shall be sanded so no seams are visible.

(e) The floor shall be constructed level, except wheelhousing, and shall be constructed in such a manner that there will be no passenger hazards, water hazards, or pockets which would endanger passenger safety. Where the floor meets the walls of the trolley , the surface edges shall be blended with a circular section of radius not less than 1/4 inch, and molding or cove shall prevent debris accumulation between the floor and wheel housings.

(f) The floor, as assembled, including the sealer, attachments and covering, shall be waterproof, resistant to wet and dry rot, resistant to mold growth, and impervious to insects. Plywood, if used, shall be no less than 3/4 inch thick American Plywood Association, marine grade, A-B special, and shall be installed with the A side up and with all edges sealed.

(g) Floor shall be laid in a manner as to be free from squeaks. Plywood shall be bolted securely through cross sills, and treated to resist decomposition.

(h) Floor covering shall be RCA Transit Floor; ribbed 5/16 inch thick on step treads and farebox area, 3/16-inch ribbed in aisle and; 1/8-inch smooth under driver and throughout remainder of the trolley. Yellow step nosing to be furnished. A yellow safety line shall be installed in aisle to rear of driver. Aluminum trim molding shall be provided for driver's area.

(i) All joints in floor covering shall be butt-cut joint type, properly sealed, and ribs shall be properly aligned to prevent gaps or edges and to facilitate cleaning. The color of the flooring shall be determined by the Procuring Agency.  

(a) Sides shall be paneled with .063" non anodized aluminum or 18 gauge hot rolled steel installed with 3/16" zinc coated aluminum rivets on all perimeter edges.

(b) The rear observation deck wall shall be paneled with .100" non-anodized aluminum and thoroughly cleaned and treated with zinc chromate primer.

(c) Roof panels shall be .050" anodized aluminum or 18 gauge steel.

(d) The roof shall be designed in a curvature depicting the original lantern roof designs of the late 1800 streetcars.

(e) Rear wheels to be covered with wheelwell skirts latched at the bottom to prevent movement while the trolley is in motion. The skirts are to be hinged at the top and include pneumatic rods to hold the skirt up for full access to tires.

(f) All panels are to be thoroughly cleaned and treated with zinc chromate primer and undercoated prior to installation, and installed while undercoating is wet. A cork tape shall be applied between the body framing and all exterior panels.  

(a) The entire roof, including the lantern section, shall be totally insulated using polyurethane foam in place thermal insulation applied 1 1/2" nominal thickness to the interior surface of the exterior roof panels.

(b) The entire underside of the coach body, wheelhousings, stepwells, passenger and driver's areas shall be sealed with an application of minimum 1/8" thick emulsion, Lubrizol or other approved, undercoating prior to installation on the chassis.  

(a) All interior side panels, including front and rear bulkheads shall be paneled with 1/4" oak plywood panels or aluminum sheets.

(b) Ceiling panels shall be 1/4" oak plywood.

(c) All perimeter edges of the ceiling are also to be trimmed with oak trim moldings.

(d) Panels are to be thoroughly cleaned and coated finish with clear polyurethane or a two part epoxy.  

8. SKIRT PANELS

 Skirt panels constructed of .100" non-anodized aluminum and extending from the top of the floor to the bottom of the coach body, shall be installed sectionally using rivets.  

  The body shall have at least one rub rail at the floor line.  

  Front and rear bumpers shall be designed to resemble the drawings submitted as part of these specifications. Bumpers shall comply with all applicable regulations, and shall have the aesthetic appearance of authentic street car bumpers.  

(a) An authentic vintage, designed, framed heavy gauge woven wire cowcatcher shall be mounted on the underneath side of the front bumper.

(b) This cowcatcher shall have the same contour from side to side as the bumper and wraps around the corners of both sides of the streetcar. The cowcatcher is to be finished in the same color as the trolley, to be approved by the customer.

(c) The cowcatcher shall be made of 12 gauge x 1-1/4" O.D. steel tubing frame covered with 7 gauge heat treated alloy expanded steel with a 1 1/2" clear open diamond pattern.  

(a) Treads  

 
(1) Front step assemblies shall be covered with 5/16" ribbed black step treads with integral yellow nosings.
(2) If a step lift in installed in the front door, all step treads shall be as provided by the manufacturer of the step lift.  

(b) Stepwells  

(1) Front step height from the ground (no load) shall be 15 inches maximum. Individual risers shall be 10 inches maximum in height and in case of more than one riser, all shall be the same height. Step tread depth to be 10 inches minimum.  
(2) The stepwell shall be modular design twelve (12) gauge stainless steel smoothly and continuously welded into OEM structure. Stepwell shall be adequately reinforced to prevent noticeable deflection when either step is loaded over the center half with a 300 pound static load.  
(3) Step edges shall be standard molded in yellow RCA flooring step edge, ribbed or approved equal.  
(4) Stepwell shall be completely enclosed and weather tight when passenger door is in the closed position.