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.
|Rear Floor||Off Side Partition||Platform|
|Rear Seats Lower Saloon||Rear Seats Lower Saloon||Roof Jig (underneath)|
|Rear End||Front End||Nearside Wing Assembley Subframe|
|Nearside Wing Assembley||Driver's Cab Front||Inter-Floor Sticks|
|Upper Saloon Sides||Rear End||Bulkhead|
|Side Frames Exterior||Hoop Sticks||Interfloor|
|Floor Complete||Side Frames Interior||Roof Jig (top)|
|Rear Partition||Forward Floor||Cab Floor|