How Limo Builders Manufacture Custom Coach Stretch Limousines

Limo builders do a lot more work than most of us realize in order to create a stretch limousine. The reason is that limos are all custom built by hand from stock cars. There are no mass production lines, welding robots, or motorized auto-picking of parts as far as custom coach building is concerned.

Here are just some of the steps involved -- in no particular order -- that limousine manufacturers go through in creating a stretch limo.

First, they buy a stock car that is going to be stretched. While you can make a limo from pretty much any type of car, some of the more popular car models used for limousines are Lincoln Town Cars, Mercedes, BMWs, Rolls Royces, Ford Excursions, and Hummers.

The limo builder then strips the interior of the car. They remove the rug, seats, interior vinyl top, and electrical wiring. Depending on the model of car the electrical can be difficult to extend because of the complexity of the wiring between the dashboard and the rest of the car. Mercedes cars are notorious for having complex wiring systems.

The limousine manufacturer then masks the windows, dashboard, door panels, and interior to prevent damage from cutting and welding sparks.

They mount the whole car on rails with rolling dollies. This will allow for separating or "stretching" the car after it is cut and at the same time keep the two halves supported and aligned.

Next, temporary supporting braces are added to the frame in order to prevent it from warping when the car is cut. The weight of the supporting steel as well as the act of cutting can cause the metal to bend.

Once the car is cut these items -- at a minimum -- are added to stretch the car.

• Extend the exhaust pipe.
• Attach new mounts and frame for the existing doors.
• Add extended electrical wiring.
• Add new floor panels.
• Add extended frame structure.
• Add supporting steel to prevent the middle part of the car from sagging.
• Add extended ceiling panels.
• Add new mounts for extra doors.
• Add more supporting structural steel and side sheet metal skin.

For the interior these custom items are usually added.

• Interior bars.
• Interior side seating.
• Mirrored ceilings.
• TV panels.
• Speakers and sound system.
• CD and DVD players.
• Extended interior top.
• Electrical lines extended for lights, interior electrical disco lights, fog machine, etc.

Finally, for the outside there is typically new carriage undercoating as well final body work to smooth out the welding edges and a new coat of primer and paint.

These are just a few highlights of what limo builders have to do in order to build a custom stretch limo that can take you and your party out on the town.