Thomas Built Buses

1930s

In 1930, Thomas Car Works was reincorporated as a stock company, with Perley Thomas making his family stockholders in Perley A. Thomas Car Works, Inc. For the last time, the company received an order for streetcars, producing 4 for Mobile, Alabama. While rail-based streetcars offered higher capacity, for public transit, automotive-based buses grew in popularity as they offered a greater degree of routing flexibility. In a transition away from streetcars, Perley Thomas produced its first trolley bus in 1933; while still drawing power from overhead wires, a trolley bus was constructed from a bus chassis; the company ultimately built a total of only two trolley buses, for Greensboro, North Carolina. For 1934, the company produced 10 transit buses for South Carolina-based Duke Power.

Following the collapse of its primary source of revenue, Thomas Car Works diversified its work, expanding into automotive refinishing and construction of bus and truck bodies. From 1929 to 1934, the company workforce decreased from 125 to nearly 10 (which included Perley Thomas and his 3 children). Eventually, a company creditor filed for receivership, with the lack of potential buyers allowing for the survival of the company.

Transition to bus construction

In 1936, Thomas Car Works secured part of a bid to produce 500 school bus bodies for North Carolina. As the company was only financially able to acquire materials for 200 bodies, North Carolina split the bid between Thomas and Hackney Brothers. Dependent on length, Thomas offered wood-bodied school buses for $195 to $225. Following the completion of its second school bus bid in 1937, the company focused nearly all production on school bus bodies. In what is a long tradition that continues to the present day, Thomas remains the primary supplier of school buses to North Carolina.

In 1938, several major innovations were introduced by the company to its school bus design, including its first steel-bodied school bus. While Perley Thomas streetcars had adopted steel construction in 1918, school bus design had slowly evolved from farm wagons, with wooden body construction continuing into the 1930s. Although not the first to construct an all-steel body, Thomas introduced one-piece roof bows, internal roll bars welded to each side of the floor/frame structure. While the design has been updated for added strength, the one-piece roof bow is in use in all school buses manufactured in North America today. In another innovation, Thomas introduced an outward-opening entry door, designed to aid egress in emergency evacuation situations.

1940s

In 1940, day-to-day operation of Thomas Car Works was turned over from Perley Thomas (who remained company president) to his three children. John W. Thomas managed company operations along with sales, along with James Thomas handling the High Point factory. Following the outbreak of World War II, as with its competitors, Thomas bus production was shifted towards the armed forces. In a contract shared with Ward Body Works, Thomas also produced various bodies for the GMC CCKW truck.

While the war had brought school bus production to a halt, the High Point factory remained utilized in civilian capacity. To supplement its armed forces production, Thomas Car Works was put to use by refurbishing streetcars. As rationing had placed increased demands on public transportation, the upkeep of existing equipment was considered a priority.

Following World War II, with a rise in student populations, Thomas Car Works began to expand its sales market beyond the South, opening dealerships across the eastern half of the United States. To better weatherproof its entry door, the company developed a reinforced rubber-covered door hinge; the rubber also covered the gap between the two door panels as they closed.

After World War II, a third generation of the family joined the company, with John W. Thomas Jr. and Perley (Pat) Thomas II, with the former becoming director of sales and the latter taking over control of government contracts.

1950s

During the decade, Thomas Car Works began exports of its product lines, establishing satellite facilities in Ecuador and Peru. From North Carolina, bodies were shipped to South America in CKD form for final assembly on locally sourced chassis.

In 1957, the Thomas Saf-T-Liner name made its first appearance, denoting updated bus bodies (with an enlarged two-piece windshield). Used full-time by 1972, the name remains in use for all full-size Thomas buses over 60 years later.

Company founder Perley Thomas died in 1958 at the age of 84; at the time of his death, Thomas retained his title of company president and also actively served as a design consultant.

1960s

In 1962, Thomas Car Works officially expanded its production beyond High Point as Thomas Built Buses of Canada, Ltd. was established in Woodstock, Ontario. At the time, the company became the third-largest producer of school buses in the United States.

To demonstrate the strength of its internal roof bows, Thomas stacked a full-size school bus on the roof of another (using a crane) in 1964; the company has subsequently repeated the demonstration several times using more recent product lines.

For 1967, to reduce blind spots in front of the bus, Thomas developed a convex blind-spot mirror. Initially mandated in North Carolina, the device (allowing a 150-degree field of vision directly in front of the bus) would be adopted by 16 other states in only two years. In various forms, blind-spot mirrors are currently required on all school buses in North America.

1970s

In the early 1970s, Thomas underwent a number of major transitions in company leadership and market positioning. Company president John W. Thomas died in 1972, giving leadership to his brother James Thomas, who retired within a year. A third generation of the Thomas family assumed control of the company leadership, with John Thomas Jr. (President) and Perley Thomas II (VP, international operations).

As Thomas Car Works had ended its involvement with streetcars since World War II, the new generation of company leaders chose a new name for the company tied closer to its current product lines; in 1972, Perley A. Thomas Car Works was renamed Thomas Built Buses, Inc (used in its emblems and marketing material since the 1950s).

Expanded school buses

Since producing its first school bus in 1936, virtually all Thomas school bus bodies had been produced in the "conventional" style: a body mated to a cowled truck chassis. While the design was the most popular configuration, the transit-style configuration allowed for a higher passenger capacity (up to 90 passengers). In the early 1970s, Thomas developed the Saf-T-Liner ER (Engine Rear) as an alternative to the Blue Bird All American. In line with other body manufacturers (Carpenter, Superior, Ward, and Wayne), Thomas was dependent on a second-party manufacturer for rear-engine chassis (using Ford, Dodge, GMC, International Harvester and Volvo).

In the early 1970s Thomas Built Buses introduced the first of its "Mighty Mite" series of buses and were the smallest conventional bus ever produced by Thomas. Most were built on Dodge D300 chassis but when production of this series ended at the main plant in High Point, NC, production was moved to Woodstock, Ontario and the Canadian built Mighty Mites used modified International Loadstar chassis.

For 1972, the Saf-T-Liner body underwent a major redesign. Along with extending the rub rails completely around the body, the front and rear roof caps were flattened (to accommodate 8-lamp warning systems), and the windshield was enlarged. Following the addition of safety upgrades to comply with safety mandates in 1977, the Saf-T-Liner body saw use in the Conventional through the end of 2006; in modified form, it remains in use with the EFX and HDX (and resized to fit the Minotour). At the smaller end of the size scale, the Saf-T-Liner body was resized to produce the Mighty Mite, a narrow-body school bus on a shorter-wheelbase conventional chassis.

In 1977, Thomas made a major change to the production of the Saf-T-Liner ER. Coinciding with a design update, Thomas introduced a company-sourced chassis, along with the front-engine Saf-T-Liner EF. With the introduction of the EF, Thomas became the first school bus manufacturer to produce its own chassis for both front and rear-engine school buses, ahead of Blue Bird by a decade (California manufacturers Crown Coach and Gillig Corporation had not produced a front-engine school bus since before World War II). As a competitor to the Blue Bird Mini Bird and Carpenter Cadet, Thomas reintroduced the Mighty Mite as a Type B bus, a school bus body paired with a stripped chassis.

1980s

The late 1970s and early 1980s was a period of struggle for all school bus manufacturers. Coupled with the slow economy, manufacturers could no longer count on the factor that had driven school bus sales for the past two decades: the entirety of the baby-boom generation had finished school; it would be years before student populations would create sufficient demand again. During this time, a number of manufacturers either encountered financial difficulty or closed their doors altogether.

At the beginning of the decade, Thomas introduced a new logo, displayed on the roofline of its buses; a "T-bus" logo replaced the previous scripted "Thomas Built Buses" company logo (still attached elsewhere to the body).

To better secure the future of the company, the Thomas family sought to raise capital for Thomas Built Buses, leading the company board to bring in the Odyssey Group investment firm to oversee the process. In return, Odyssey Group received a stake in the company (remaining under full family control).

In the early 1980s, Thomas launched a diversification of its product line, expanding its presence in the transit bus segment. Derived from the Saf-T-Liner, the Transit Liner was developed for commercial use. In 1982, the CL960 "Citiliner" was introduced as a dedicated transit bus; while sharing its underpinnings with the Saf-T-Liner ER, the two-door CitiLiner was rebodied (with a sloped windshield). Sharing its body with the CL960, the Chartour was developed for charter use, using a single entry door.

Product innovations

Following the mid-1970s launches of the Wayne Busette and Blue Bird Micro Bird, Thomas would launch its own cutaway-chassis school bus, the Thomas Minotour, in 1980. Alongside the small Minotour, Thomas introduced the WestCoastER, a heavy-duty variant of the Saf-T-Liner ER marketed against Crown Supercoach and Gillig Phantom school buses. Sold only in 84 and 90-passenger configurations, the WestCoastER used heavier-duty driveline and suspension components; tandem rear axles were offered as an option.

In 1989, Thomas introduced a second conventional-style bus to its model line, launching the Thomas Vista school bus. To optimize forward sightlines for drivers, the layout of the driver's compartment and forward chassis were redesigned. Along with a shorter hood and redesigned windshield, the engine and front axle were repositioned. In contrast to a standard conventional bus, the driver of the Vista sat beside the engine (rather than behind it).

1990s

In 1991, the Saf-T-Liner transit-style buses saw their first redesign since 1977. The ER and WestCoastER were given a much larger windshield, redesigned driver's compartment, and saw the introduction of several new diesel engines. To better compete with the Blue Bird TC/2000 and Ward Senator (which became the AmTran Genesis), Thomas replaced the Saf-T-Liner EF with the All Star, using an Oshkosh-produced chassis. The Thomas Vista continued production, shifting chassis in 1991 from General Motors to a variant of Navistar chassis shared with the Saf-T-Liner Conventional.

In 1992, the fourth generation of the Thomas family took over daily operations of the company (becoming the first family-owned school bus company to do so).

During the mid-1990s, the company began development of environmentally cleaner buses, with compressed natural gas (CNG) school buses entering production in 1993; several battery-electric school buses were produced in 1994 as prototype vehicles.

By 1996, Thomas had become the largest school bus manufacturer in the United States (by market share). To keep up with added demand, the company opened a third factory in Monterrey, Mexico. As a design change, the "T-bus" roof emblem (used since the early 1980s) was replaced by a scripted Thomas Built Buses emblem (its predecessor).

During the later 1990s, Thomas Built Buses would undergo a number of significant changes, with some that have changed the future of school bus manufacturing. For the 1997 model year, Freightliner introduced the Freightliner FS-65 school bus chassis. Derived from the Freightliner FL60/FL70 medium-duty trucks introduced in 1995, the FS-65 chassis was paired with the Saf-T-Liner Conventional body, after several modifications (distinguished by the addition of a 4-piece windshield).

Transit expansion

During the 1990s, Thomas modernized and expanded its product range within the transit segment. Alongside the Chartour and CL960/Citiliner, Thomas marketed Transit Liners, commercial derivatives of the Saf-T-Liner school buses, along with commercial versions of the Minotour and Vista. A dedicated transit bus derived from the Saf-T-Liner ER, the TL960 was a two-door bus that offered an integrated wheelchair ramp as an option.

In 1999, Thomas entered a joint venture with British bus manufacturer Dennis to import the Dennis Dart SLF (in CKD form). Following assembly by Thomas in North Carolina; while badged as Thomas vehicles (the Thomas Dennis SLF200), distribution of the low-floor buses was undertaken by Orion Bus (itself becoming a Daimler subsidiary in 2000).

Company acquisition

Into the late 1990s, Thomas Built Buses remained a family-owned company, controlled by the fourth generation of the Thomas family and the Odyssey Group. Following the departure of Wayne Wheeled Vehicles from the manufacturing segment, Thomas became the largest manufacturer, holding a 34% market share in 1996. The same year, the Thomas family sold a majority stake of the company to the Berkshire Partners equity firm.

Freightliner entered school bus manufacturing as a chassis producer in May 1996, unveiling the Freightliner FS-65 (derived from its FL60/FL70 Business Class medium-duty truck); developed in cooperation with Thomas, the first production Freightliner-chassis buses were produced at the beginning of 1997. The product launch marked the first completely new school bus chassis since 1980, with Freightliner becoming the first new cowled-chassis manufacturer since the 1977 withdrawal of Dodge.

Following its collaboration with Thomas in developing the FS-65 chassis, in October 1998, Freightliner acquired Thomas Built Buses in its entirety from the Thomas family and the Berkshire, retaining company president John W. Thomas III. The largest school bus manufacturer in North America at the time, Thomas Built Buses was the last major manufacturer operating under family control. At the time, Freightliner was undergoing a series of company acquisitions to diversify its product range beyond highway trucks. Along with acquiring the rights to the Ford heavy-truck line (and Ford Cargo) in 1997 (continued as Sterling Trucks), Freightliner acquired Thomas alongside the chassis production of Oshkosh Corporation (1995), American LaFrance (1996).

For school bus manufacturers, the 1990s marked a period of association between major body and chassis manufacturers. In 1991, Navistar began its purchase of AmTran (completed in 1995); a year later, Blue Bird entered in a supply agreement with General Motors for conventional bus chassis. 1998 marked both the purchase of Thomas by Freightliner and the sale of Carpenter to Spartan Motors (its front/rear-engine chassis supplier).

At the end of the 1990s, several changes made to the Thomas product line were related to its purchase by Freightliner. At the end of 1998 production, Navistar ended its chassis production for the Vista; as the Vista body was developed solely for its chassis, Thomas discontinued the model line. While Freightliner did not purchase the Ford medium-duty truck range or the school bus chassis derived from it, Ford ended production of the latter after 1998. Consequently, from 1999 onward, the Saf-T-Liner Conventional was limited to Navistar or Freightliner chassis (along with AmTran/Ward, Carpenter, and Wayne, the last General Motors chassis for a Thomas bus was produced in 1991).

TL960 - rear-engine transit bus derived from Saf-T-Liner ER

Chartour- rear-engine transit bus

CL960 - rear-engine transit bus

SLF200 (Super Low Floor) series - badge engineered transit bus built under license from Dennis Specialist Vehicles, based on the Alexander ALX200. It had a Dennis Dart SLF chassis.