For Conversion Limos (most common):
1. Vehicle Selection: A suitable car is chosen as the base. This is usually a high-quality sedan or SUV known for its reliability and structural integrity. Popular choices include luxury brands like Lincoln, Cadillac, and Mercedes-Benz.
2. Disassembly: The vehicle undergoes partial disassembly. This involves removing sections of the body, particularly the rear passenger compartment and sometimes parts of the roof. The extent of disassembly depends on the desired length and features of the limo.
3. Stretching (the crucial step): This is where the magic happens. The chassis is lengthened using various techniques. These may involve:
* Cutting and inserting a section: The chassis is cut in the middle, and a specially fabricated section is inserted. This section needs to perfectly match the original chassis in terms of strength and rigidity.
* Inserting pillars/sections: Sections are added between existing pillars to extend the roof and body.
* Advanced techniques: Some manufacturers use more advanced methods involving specialized computer-aided design (CAD) and manufacturing techniques for precise and stronger joins.
4. Bodywork and Welding: The extended chassis is meticulously welded and reinforced to ensure structural integrity. New body panels are fabricated and fitted to seamlessly blend with the original car's body. This process demands high precision and skill.
5. Interior Design and Installation: This is where the limo really comes to life. The interior is completely redone. This includes:
* Upholstery: High-quality leather, fabrics, and other luxurious materials are used.
* Seating: Comfortable seating arrangements are installed, often including reclining seats, captain's chairs, and even sofas.
* Features: This is where the limo's unique features are added such as bars, entertainment systems (TVs, sound systems), lighting, climate control, partitions, and sometimes even champagne coolers, minibars, and Wi-Fi.
6. Electrical and Mechanical Systems: The extended vehicle's electrical systems, including wiring, lighting, and entertainment systems, need to be carefully integrated. Mechanical systems also need to be adjusted for the increased length and weight.
7. Testing and Refinement: Rigorous testing is carried out to ensure the limo functions flawlessly and meets safety standards. Any necessary adjustments or refinements are made.
8. Finishing and Detailing: The final touches are applied, including polishing, waxing, and a thorough cleaning.
For Purpose-built Limos:
These are less common and generally more expensive. They are designed and built from scratch, rather than being conversions. The process is similar but begins with designing and engineering a completely new chassis and body, incorporating all the desired features from the start.
Regardless of the method, building a limo is a highly specialized process requiring skilled welders, fabricators, mechanics, interior designers, and electricians. The final product is a luxury vehicle designed for comfort, style, and often, a unique experience.
