Abstract: A truck body includes a rigid aluminum frame, the frame comprising: a load floor and underbody comprising structural extrusions oriented longitudinally; subassemblies comprising aluminum extrusions formed into frames defining the body walls; and, at least one subassembly comprising aluminum extrusions formed into a frame defining the body roof, and wherein the load floor, wall subassemblies, and roof subassembly are fastened together to form a rigid final assembly. Roll formed steel tubular members may be substituted for the aluminum extrusions. The invention may further be adapted to make modular trailers that can be customized by choosing among different wall and roof modules. Related assembly methods are also disclosed.

Abstract: An assembly station for interconnecting a chassis and a body of a vehicle comprises a first carrier to support the chassis. A second carrier is suspended in a positive z-direction with respect to the first carrier and includes a plurality of spaced apart rests adapted to support the body prior to interconnecting the chassis and the body. A plurality of supports are coupled to the second carrier and spaced apart from the body when the body is supported on the rests. A portion of each of the supports is pivotable from a first position in a path of travel of the chassis to a second position outside of the path of travel of the chassis. The first carrier is moveable relative to the second carrier. The supports are adapted to engage the chassis and simultaneously support both the chassis and the body when the supports are in the first position.

Abstract: An assembly station for interconnecting a chassis and a body of a vehicle comprises a first carrier to support the chassis. A second carrier is suspended in a positive z-direction with respect to the first carrier and includes a plurality of spaced apart rests adapted to support the body prior to interconnecting the chassis and the body. A plurality of supports are coupled to the second carrier and spaced apart from the body when the body is supported on the rests. A portion of each of the supports is pivotable from a first position in a path of travel of the chassis to a second position outside of the path of travel of the chassis. The first carrier is moveable relative to the second carrier. The supports are adapted to engage the chassis and simultaneously support both the chassis and the body when the supports are in the first position.

Abstract: A method of interconnecting a vehicle chassis and body includes supporting the chassis on a first carrier and supporting the body on a second carrier suspended in a positive z-direction with respect to the first carrier; translating the first carrier in the positive z-direction; interconnecting the chassis and the body; and shifting supports coupled to the second carrier and spaced apart from the body from a first position in a path of travel of the chassis to a second position outside of the path by pivoting each support about a pivot axis. The method also includes shifting the supports from the second to the first position by pivoting each support about the pivot axis; translating the first carrier in a negative z-direction toward the supports; and supporting the interconnected chassis and body on the second carrier by engaging the chassis with the plurality of supports in the first position.