Cutaway van chassis

Cutaway van chassis are used by second stage manufacturers for a wide range of completed motor vehicles. Chassis cabs are similar vehicles, Especially popular in the United States, they are usually based upon incomplete vans, such as Bohdan-2310, Chevrolet Chevy Van/GMC Vandura, Chevrolet Greenbrier, Chevrolet Astro/GMC Safari, Chevrolet Express/GMC Savana, Citroën Berlingo, Citroën Nemo, Citroën Jumpy, Citroën Jumper, Dodge Sprinter, DKW Schnellaster, Fordson Thames 400E, Ford E-Series, Ford Aerostar, Force Traveller, Ford Transit Connect, Ford Transit, Ford Transit Custom, Foton View, Fiat 238, Fiat 241, Fiat 242, Fiat Doblò, Fiat Scudo, Fiat Ducato, Fiat Talento, Hyundai Starex, Hyundai H350, Iveco Daily, JAC Sunray, King Long Kaige, Kia Besta, Kia Pregio, LDV Convoy, LDV Maxus, LDV Pilot, Mercedes-Benz Sprinter T1N, Mercedes-Benz Sprinter NCV3, Mercedes-Benz Sprinter VS30, Mercedes-Benz T2, Mercedes-Benz Vario, Mercedes-Benz Citan, Mercedes-Benz MB100, Mercedes-Benz TN, Mercedes-Benz Vito W638, Mercedes-Benz Vito W639, Mercedes-Benz Vito W447, Nissan Caravan, Nissan Kubistar, Nissan Interstar, Nissan NV200, Nissan NV300, Nissan NV400, Nissan Primastar, Opel Combo, Opel Movano, Opel Vivaro, Peugeot Expert, Peugeot Bipper, Peugeot Boxer, RAF-977, RAF-2203, Renault Master, Renault Kangoo, Renault Trafic, Renault Estafette, SsangYong Istana, Škoda Praktik, Toyota HiAce H200, Toyota HiAce H300, Toyota ProAce, Tata Winger, Tempo Traveller, Volkswagen LT, VW Crafter, VW Caddy, Volkswagen Type 2 (T1), Volkswagen Type 2 (T2), Volkswagen Type 2 (T3), Volkswagen Transporter T4, Volkswagen Transporter T5, Volkswagen Transporter T6, ZAZ Sens Van, GAZ GAZelle, GAZelle-NEXT, GAZ Sobol, GAZ Sobol-NEXT, and UAZ-452 made by manufacturers such as Chrysler Corporation, Ford Motor Company, and General Motors which are generally equipped with heavier components than most of their complete products. To these incomplete vehicles, a second stage manufacturer adds specific equipment and completes the vehicle. Common applications of this type of vehicle design and manufacturing includes small trucks, school buses, recreational vehicles, minibuses, and ambulances.

History

Following the initial popularity of Volkswagen's imported minibuses, vans made by the domestic manufacturers were developed and became popular in the United States in the 1960s. By the early 1970s, Chrysler Corporation, Ford Motor Company, and General Motors were all manufacturing many models of passenger and utility vans. The Dodge passenger vans of Chrysler had a maximum seating capacity of 14 persons plus the driver, and came to be commonly known as 15 passenger vans, joined by similar sized models by the other manufacturers years later.

Conversions for personal motor homes became very popular, drawing the interest of recreational vehicle manufacturers. Based upon that, cutaway van chassis were developed in the early 1970s to accommodate demand for conversions which were heavier and wider than the standard production vans completed by the major auto and truck manufacturers (i.e. Chevrolet-GM, Dodge, and Ford). As they began working on bigger models of their popular light-duty van products, they developed cutaway van chassis solely for use by second stage manufacturers.

Design, body-builders

As produced by the first stage (van) manufacturers, a cutaway van chassis generally features a van front end and cab design. The body ends immediately behind the driver and front passenger seats, and is usually covered by temporary plywood or heavy cardboard material for shipment to the various second stage manufacturers. It was soon known by the name "cutaway van chassis" in recognition of this feature.

Second stage manufacturers, known in the industry as "body-builders," build such products as bus and truck bodies, motor homes, and other specialized vehicles. Neither their product, nor the first stage portion, legally defined as an "incomplete motor vehicle" under the Federal Motor Vehicle safety Standards (FMVSS) in the US. are fully compliant with requirements for a complete motor vehicle. Neither portion can be licensed or operated lawfully without the other. Many cutaway chassis are equipped with dual rear wheels and can handle greater weight loads than the basic vans upon which they were based.

Busette: first of the cutaway school buses

Busette, developed by Wayne Corporation in 1972, was the first successful small school bus to be based on a cutaway van chassis with dual rear wheels. With a low center of gravity and the dual rear wheels, Busette provided an exceptional combination of increased seating capacity and handling stability over conventional vans and van conversions.

By the early 1980s, all five of the major school bus body companies in the United States had developed competing products built on the cutaway van chassis. These manufacturers were joined by several others which specialized in small school buses. In the early 1990s, Mid Bus, an Ohio manufacturer specializing in small school buses, purchased the tooling and product rights to build the Busette from Wayne Corporation, and produced Busettes for a few more years. In modern times, more small school buses are based upon cutaway van chassis than any other type. Most school bus body builders also produce models for non-school use, often called a "commercial minibus".

Recreational vehicles (motor homes)

A recreational vehicle (or "RV") is a motor vehicle dually used as both a vehicle and a temporary travel home. They are also called "motor homes" and are very popular in North America. By the mid 1970s, recreational vehicle builders were building models based upon cutaway van chassis.

Within the industry, a motor home based upon a cutaway van chassis is a Class C motor home. It is built on a truck chassis with an attached cab section, which is usually cutaway van chassis based (but may also be pickup truck based or even large truck based). They are characterized by a distinctive cab-over profile, the "cab-over" containing a bed or an "entertainment" section.

Commercial minibuses

Seeking to expand product offerings, several recreational vehicle manufacturers, notably Champion, ElDorado National, Turtletop, and others also developed minibus models using cutaway van chassis and body construction similar to their motor homes. With their products, they joined the school bus body companies in seeking and expanding markets.

Minibuses customarily have a seating capacity of between 8 and 30 seats. They are used in a wide variety of applications. In a public transport role, they can be used as fixed route transit buses, airport buses, flexible demand responsive transport vehicles, share taxis or large taxicabs. Wheelchair accessible minibuses can also be used for paratransitype services, by local authorities, transit operators, hospitals or charities. Private uses of minibuses can include corporate]] transport, charter buses, tour buses, and for non-profit organizations such as churches.

Ambulances

In the United States, the 1973 National EMS Systems Act, which was passed by Congress in 1974, and implemented four years later (in 1978), required that communities receiving federal funds for their programs had ambulances that met new federal specifications. The regulations included minimum width and other requirements which virtually eliminated passenger-based vehicles. The last American-made automobile-based ambulance was built in 1978.

Most US ambulances are now defined by what are known as the "Federal KKK-1822 Standards." Designs based upon the cutaway van chassis with modular bodies are defined as Type III. (Type I uses pickup truck chassis and Type II are straight conversion of van without a modular body).

Many of these models have access between the driver and the patient care area, which for some applications, is a favorable feature over a full cab chassis with a modular box.

The same standards are practiced in Canada, but the legislation defining the types are provincially determined.

Delivery trucks

Cutaway van chassis also found a popular application for delivery vehicles and small trucks. They featured a size and weight capacity similar to the earlier step van model trucks and more of an automobile style cab area.

With easier adjustment of drivers accustomed to operating automobiles than most type of small trucks, they found especially strong acceptance in rental truck fleets. Usually, the entrance is via a large door in the rear which opens almost the full width of the body. Some models such as those offered by U-Haul use small dual rear wheels to provide the least amount of intrusion of the rear wheel wells into the cargo area.

See also

• Bus manufacturer
• Recreational vehicle
• Ambulance
• Glossary Index

External links

• Blog about Sprinter Vans and other Conversion Vans