Routemaster
Jigs
Since
the Routemaster was a monocoque and chassis-less, the front & rear
assemblies were delivered to Park Royal on trucks rather than being driven, as
was usual with conventional chassis. Whilst most of the mechanical units
came from AEC some were delivered from Leyland and these assemblies themselves
were an amalgamation of other manufacturer's units.
Construction
of the Routemaster at Park Royal was a very different process than that used for
conventional buses. Not only was the bus chassis-less but the large order and
the prerequisite of interchangeability (of unit parts) demanded the use of
production line techniques that other small-order/value production would not
allow.
Jigs
were used throughout to ensure compatibility between all Routemasters and the
following images are a set of the jigs used in August 1961.
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| Rear
Floor |
Off
Side Partition |
Platform |
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| Rear
Seats Lower Saloon |
Rear
Seats Lower Saloon |
Roof
Jig (underneath) |
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 |
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| Rear
End |
Front
End |
Nearside
Wing Assembley Subframe |
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 |
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| Nearside
Wing Assembley |
Driver's
Cab Front |
Inter-Floor
Sticks |
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 |
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| Upper
Saloon Sides |
Rear
End |
Bulkhead |
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 |
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| Side
Frames Exterior |
Hoop
Sticks |
Interfloor |
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 |
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| Floor
Complete |
Side
Frames Interior |
Roof
Jig (top) |
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 |
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| Rear
Partition |
Forward
Floor |
Cab
Floor |
| |
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|
| |
Engine
Shield |
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