The Clubman/Turbostar/Electrostar platform is a modular design, optimised for speedy manufacture and easy maintenance. It consists of an underframe, which is created by seam-welding a number of aluminium alloy extrusions, upon which bodyside panels are mounted followed by a single piece roof, again made from extruded sections. The car ends (cabs) are made from glass-reinforced plastic and steel, and are huck-bolted onto the main car bodies. Underframe components are collected in ‘rafts’, which are bolted into slots on the underframe extrusion. The mostly aluminium alloy body gives light weight to help acceleration and energy efficiency. Electrostar units have a shorter 20 m long version of the Turbostar's 23 m long body.
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