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Australian engineering & manufacturing · Mortdale NSW
If you've caught a train on Australia's east coast, you've probably sat on our work.
Classic Coachworks designs, manufactures and refurbishes rail interiors — seating, fire-retardant foams, GRP, trim, blinds and upholstery — for nearly every passenger fleet in Australia.
EN 45545-2 · HL2 / HL3
AS 1530
BS 6853
CCW R201 · QR & SYDNEY TRAINS APPROVED
446
Tangara double-deck carriages — interior overhaul and Technology Upgrade Phase 2 seating and GRP.
15+
Passenger fleets supported across NSW, Queensland and Victoria — refurbishment, OEM supply and depot programs.
53 sets
OSCAR four-car double-deck sets — full interior seat refurbishment now underway.
60+
Mechanical engineering interns hosted over ten years with UNSW, USyd, UTS and Western Sydney University.
Why Choose Classic Coachworks?
We make things. And we make things happen.
One site in Sydney covers the full life of a rail interior component — from 3D scan and mould design through foam moulding, cut-and-sew and GRP, to fleet-wide refurbishment and weekly depot maintenance programs.
DESIGN + REVERSE ENGINEERING
Obsolete part? We rebuild the drawing
3D scanning and model creation captures complex legacy shapes precisely — cushions, backrests, armrests, handles — including mould design and manufacture for parts whose OEM no longer exists.
MANUFACTURING
Foam, GRP, elastomers and trim under one roof.
Custom foam formulations tuned for fire retardancy, hardness and fatigue resistance; moulded silicon and integral skin foams; GRP tooling and production; industrial cut-and-sew upholstery.
FLEET PROGRAMS
Refurbishment at fleet scale.
Complete interior overhauls, depot support and standing maintenance programs — from a weekly seat program on Sydney's Waratah fleet to full-fleet XPT refurbishment and overhaul.
FLEET EXPERIENCE
Two decades of rolling stock interiors.
TANGARA
Sydney Trains
446 carriages — interior overhaul, TTU Phase 2 seating & GRP, cab blinds
OSCAR
Sydney Trains
53 four-car sets — full interior seat refurbishment, GRP panels, armrests
WARATAH / MILLENIUM
Downer
Seat foams, covers and a standing weekly maintenance program
NIF MARIYUNG
TfNSW / Hyundai Rotem
Mock-up fit-out — seating, GRP nose cone, flooring, 3D scanning for carriage acceptance
XPT
NSW TrainLink
Full fleet refurbishment and overhaul — seats, curtains, GRP nose cone, diesel fleet support
XPLORER / ENDEAVOUR
NSW TrainLink
Complete seat refurbishment, fire-retardant foams, interior maintenance
NGR
Queensland Rail
OEM — fire-retardant seating foam, seat cover cut & sew
IMU / SMU
Queensland Rail
Major seat refurbishment 100/200 & 120/220 — reverse-engineered foam and covers
L - SERIES
Queensland Rail
Spirit of the Outback — major seat refurbishment, GRP design, tooling and production
SYDNEY LIGHT RAIL
Transport for NSW
Window replacement, LED lighting integration, GRP collision repairs, driver seats
XTRAPOLIS / SPRINTER / VLOCITY
Transport Victoria
Seat cover design, cut & sew; refurbishment; VLocity kitchen upgrades
MPTV
Sydney Trains
Driver and crew seat refurbishment compliant to EN 45545-2
MATERIALS & COMPLIANCE
Fire performance you can put in a tender.
Every material we supply is tested against the standards your submission will be judged on. Our EN 45545-2 compliant range spans the full interior:
CCW R201 GRP resin is compliant to EN 45545-2 HL2 and approved by Queensland Rail and Sydney Trains for new parts and repairs. In-house vertical burn testing verifies fabrics before they ever reach a carriage.
FROM OUR FOAM LAB
Kradal™ — the floor that catches every fall.
The same foam engineering that protects rail passengers now protects aged care residents. Kradal Smart Foam is an impact-absorbing floor underlay independently trialled to reduce fall-injury likelihood by up to 59% — Assisted Living Product of the Year, Asia Pacific Eldercare Innovation Awards 2026.
PEOPLE & PARTNERSHIPS
Built in Sydney. Building Engineers.
University partnerships
60+ mechanical engineering interns over ten years, in partnership with UNSW, the University of Sydney, UTS and Western Sydney University — and many now work here full-time.
Beyond rail
The same materials engineering serves defence, bus, marine and aerospace — plus safety nets manufactured and supplied to rail depots Australia-wide.
WORK WITH US
Tell us the part, the fleet, or the problem.
From a single obsolete armrest to a 446-carriage overhaul — if it's inside a carriage, we've probably made it, fixed it, or can reverse engineer it.
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