Abstract: A method for manufacturing a bunk assembly for a transit vehicle is provided. The method includes forming an upper shell and forming a lower shell. The method further includes installing a frame between the upper shell and the lower shell and joining the upper shell and the lower shell together to form a support panel. The method further includes drilling a fill hole and a vent hole in the lower shell, the vent hole having a first diameter, and filling the support panel with foam via the fill hole and such that air contained within the support assembly is vented through the vent hole. The method further includes redrilling the vent hole to a second diameter to form a mount hole, the second diameter being greater than the first diameter, and mounting hardware to the support panel at the mounting hole.