Type: Public, funded as the maintenance arm of Transport For London

Specialty: Bus Refurbishment

Dates of Operation: Opened in 1956, Closed in 1986

Location: Elstree, Hertfordshire, England

Overview: Aldenham Bus Works is legendary in its revolutionary approach to bus maintenance and repairs. Stationed at a factory constructed during WWII, Aldenham Works specialized in taking buses after years of service and making overhaul repairs to make older buses run like new and improving safety.

Technique: When buses from the London Fleet arrived at Aldenham Works they were lined up on an inspection row. A team of up to 4 or 5 Mechanics lead by a Foreman would meticulously inspect a bus on arrival identifying every single part and its condition, if it needed to be replaced it would be marked as such, if repairs needed to be made to specific components the Foreman would note these findings in his logs so the next team would be aware of them.

After the bus has had all of its major defects identified, the buses were towed with a special mechanical dolly to the second inspection area. Here a second team of mechanics begin the process of separating the body frame from the chassis. The mechanics repaired the frame and chassis independently of one another. The frame and chassis were given serial numbers so that they were rejoined correctly at the end of the assembly line.

Body Repairs: The Body generally had its Windows, Advertisements, Seats and it some circumstances the Floor removed before heavier work was completed. Next, Interior and Exterior body panels were removed so mechanics could take a better look at the frame. If the frame was corroded or rusting away, repairs were made and the frame was strengthened. Body panels were recycled for new ones. Headlights were replaced and new destination signs were fitted.

After the new body panels were fitted the frame was repainted in standard bright red London Transport Livery and new windows and hand rails were secured on the inside.

Chassis Repairs: Engine Mechanics would tow the chassis into the Engine Repair Bay and completely overhaul the engine block with new components. The Transmission/Gearbox would receive a similar treatment. The steering wheel and column was replaced for safety as well as repairs to the axles. Mechanics would fit brand new braking systems as they are one of the most used components and one that wears out quickly. New Tires and rims were installed and then a mechanic would drive the chassis onto a test track to check everything works as it should before the body was mounted back on. A second test drive would take place to insure the body and chassis were rejoined securely. This practice however fell out of favor because the Body sometimes took longer to repair than the chassis. Because of the interchangeability of the Routemaster, the bodies and chassis could be joined to any set.

Final Inspection: After the Chassis and Body are joined and final preparations were made. A Lead Mechanic and the Foreman would take the bus on one final run to ensure every repair was made. Sometimes a second coat of paint was applied. License Plates were put back on and the final paperwork was completed. After the bus is reborn at Aldenham Works, it is taken back to its assigned garage in London where it resumes its normal duties a brand new bus.

Additional Services: Aldenham Bus Works also repaired buses involved in accidents and served as proving ground for new bus designs before they were put on the streets of London. In some circumstances, New bus drivers reported here to gain additional experience driving the buses in a controlled environment first before training on the streets of London.