Historical Background & Overview

• First stretch limousines built around 1928
• Originally transported big bands and musical equipment
• Modern luxury sedans with extended chassis for special occasions
  • Weddings, proms, nights on the town
• 475 hours of work required to transform luxury sedan into stretch limo
• Complete transformation takes 21 days

Initial Preparation & Cutting Process

• Workers cut ordinary-sized car in half using cutting wheels
• Interior stripped away before cutting begins
• Components removed: gas tank, drive shaft
• Inner support structure cut away
• Floor cut across with reciprocating saw
• Car completely severed in half
• Back half wheeled away from front half
• Back half positioned at exact assembly spot

Frame Construction & Steel Work

• Construction department inserts steel frame rails into front half
• Rails inserted on both sides of front half
• Rails then inserted into back half
• Frame rail length measured for squareness verification
• Distance between halves verified for correct limousine proportions
• Rails welded to frames of both front and back halves

Drive Shaft & Floor Installation

• Drive shaft tunnel positioned (houses steel drive shaft and exhaust pipes)
• Tunnel welded to original vehicle tunnel
• Floor made of galvanized steel positioned
• Floor welded to frame rails and tunnel

Roof & Structural Components

• Steel roof rails welded into place
• New rails connected to original vehicle roof rails
• Vertical side post of hardened steel welded
• Post checked with level for perfect vertical alignment
• Post base welded to floor frame
• Roof panel made of galvanized steel installed

Interior Framework & Body Panels

• Limousine bar installed
• Steel seat frames already installed
• Outer body panel with hardened steel crash bar installed
• Panel screwed into place temporarily
• Screws removed once panel bonds solidly to frame

Paint & Finishing

• Three coats of paint sprayed on
• Two coats of protective clear coating applied
• Laminated safety side glass installed after painting complete

Exterior Detailing

• Contact cement sprayed on roof for vinyl top preparation
• Vinyl stretched across roof
• Fabric pressed into crevices by hand
• Excess vinyl carefully trimmed
• Chrome molding strip pressed into place on vinyl top

Interior Installation

• Interior department installs leather seat backs
• Leather bench seat installed
• Original rear seat reupholstered to match
• Original rear seat returned to back of limousine

Electrical & Systems

• Systems installer connects electrical systems
• Control center located behind driver's seat
• Panel with relays and fuses installed
• Original center console reinstalled
• Video monitor installed

Final Assembly & Testing

• Floor mats rolled out
• Acrylic disco bar lighting system tested
• Test drives conducted
• Quality control checks completed