The SportChassis Process: From Chassis to SportChassis
The SportChassis Production Line
Creating The Ultimate Pickup Line™ isn't easy, but it's a labor of love. Beginning with the Freightliner M2 Business Class Chassis, adding top-notch materials and craftsmanship, and following up with ourstanding customer service is what really takes a Chassis to a SportChassis.
The Chassis
Safety, security and style all start with the foundation. Powered by the Mercedes Benz MBE4000 series and Cummins ISC engines, the Business Class M2 106 and 112 chassis delivers the strength and performance you need to maximize productivity day in and day out. The 55 degree wheel cut provides outstanding maneuverability in tight urban situations and provides a functional, safe and stylish way for you to take care of business.
Interior & Electronics
The chassis moves into the production process beginning with an initial inspection to ensure that any challenges are detected before the real work begins. SportChassis continuously refines their LEAN manufacturing process ensuring the best materials, efficient prodution and consistent results.
After the complete inspection the chassis moves into the production line where it will begin its journey to becoming a SportChassis. Moving along the assembly line every 3 hours, a series of 9 stations take the once bare interior into the comfortable, safe, secure and quiet SportChassis.
In parallel the bed and other components are being produced, ready to join the Chassis.
Fabrication & Exterior
The SportChassis body sub-frame consists of .125 extruded aluminum tubing mounted to 3 inch solid aluminum sleeper rails. The sub-frame is spaced and reinforced in such a manner as to maximize carrying capacity while providing a near perfect surface for exterior skin attachment.
All body cutouts for lighting installation, jambs and doors, compartments and fender openings have no sharp edges or burrs, and are cut so that edges have a machine finish. By using CNC (technology, consistent tolerance of 0.004” is maintained for absolute quality and maximum redundancy. This means if your vehicle is ever damaged, any blemished aluminum part can be replaced with its exact replica.
Each SportChassis compartment is CNC-routed and break formed to ensure tight tolerances and the utmost durability.
The body compartment doors are constructed using .125 aluminum skins fastened to extruded frames and mounted in counter-extruded jambs. This allows our door to be flush with the body side skin when closed.
Stainless steel piano-type hinges run the full height of the door frame. As protection from the effects of electrolysis and galvanic corrosion, each exterior door has an inert barrier strip installed between the hinge strap and the door jamb
Each door is gasketed with a closed-cell neoprene gasket completely encircling the door with an unbroken seal. The seal does not come in contact with the striker pins, latches or hinges, which prevents the intrusion of moisture and/or dust into the compartments when the doors are closed.
The body side skins are .125 smooth aluminum and are cut using CNC technology. Further, each side skin is attached to the sub-frame using aircraft adhesive and break-formed cap rails. This prevent warping and inconsistencies due to welding and misalignment.
To mate the skins to the frame work, Freightliner Specialty Vehicles features a unique jig and trolley system. This means that the tubing is always square and that the welds, inner and outer, are applies and inspected at eye level. This insures a construction and weld quality second to none.
Once the bed is complete, it moves to the paint shop where computer mixed DuPont materials are applied in a space age paint booth by some of the best finish artists in the business. The process ensures that finishes are consistent to mil specs and hold both their adhesion and luster for years of quality service.
Quality Assurance
After leaving the paint shop, it's time for another full inspection and detailing. Ensuring that all components, installation, and materials exceed expection is a core mission of the Quality Assurance department. This staff of experience professionals drawn from all areas of manufacturing process possess the hands-on knowledge and expertise recognize any problem or imperfection and eliminate it.
Additional customization and branding finish out process including road tests, electronic shakedown, and that personal touch that concludes the journey from Chassis to SportChassis.
Customer Service
Quality is just the beginning. Customer service is a vital part of what we do. Throughout the manufacturing process, moving through the sales process, and throughout the life of the vehicle, SportChassis' number one goal is customer satisfaction. Our Service and Warranty department work tirelessly provide routine services and answer questions about this magnificient machine.
