Blue Bird (BLBD) 10-Q 14 May 20 2020 Q2 Quarterly report Financial data

Document and Entity Information

Document and Entity Information - shares	6 Months Ended
	Apr. 04, 2020	May 08, 2020
Document and Entity Information [Abstract]
Entity Registrant Name	Blue Bird Corp
Entity Central Index Key	0001589526
Current Fiscal Year End Date	--10-03
Entity Filer Category	Accelerated Filer
Document Type	10-Q
Document Period End Date	Apr. 4, 2020
Document Fiscal Year Focus	2020
Document Fiscal Period Focus	Q2
Amendment Flag	false
Entity Common Stock, Shares Outstanding		27,027,272
Entity Emerging Growth Company	false
Entity Small Business	false
Entity Shell Company	false
Entity Current Reporting Status	Yes

Condensed Consolidated Balance

Condensed Consolidated Balance Sheets - USD ($) $ in Thousands	Apr. 04, 2020	Sep. 28, 2019
Current assets
Cash and cash equivalents	$ 34,086	$ 70,959
Accounts receivable, net	7,082	10,537
Inventories	143,942	78,830
Other current assets	13,257	11,765
Total current assets	198,367	172,091
Property, plant and equipment, net	104,541	100,058
Goodwill	18,825	18,825
Intangible assets, net	53,176	54,720
Equity investment in affiliate	10,986	11,106
Deferred tax assets	3,891	3,600
Finance lease right-of-use assets	6,086	4,638
Other assets	228	375
Total assets	396,100	365,413
Current liabilities
Accounts payable	116,007	102,266
Warranty	8,345	9,161
Accrued expenses	18,111	28,697
Deferred warranty income	8,545	8,632
Finance lease obligations	734	716
Other current liabilities	11,889	10,310
Current portion of long-term debt	9,900	9,900
Total current liabilities	173,531	169,682
Long-term liabilities
Revolving credit facility	30,000	0
Long-term debt	168,715	173,226
Warranty	13,053	13,182
Deferred warranty income	14,403	15,413
Deferred tax liabilities	374	168
Finance lease obligations	5,419	3,921
Other liabilities	11,862	12,108
Pension	43,806	45,524
Total long-term liabilities	287,632	263,542
Guarantees, commitments and contingencies (Note 6)
Stockholders' deficit
Preferred stock, $0.0001 par value, 10,000,000 shares authorized, 0 shares issued at April 4, 2020 and September 28, 2019	0	0
Common stock, $0.0001 par value, 100,000,000 shares authorized, 27,027,272 and 26,476,336 shares outstanding at April 4, 2020 and September 28, 2019, respectively	3	3
Additional paid-in capital	87,408	84,271
Accumulated deficit	(46,691)	(45,649)
Accumulated other comprehensive loss	(55,501)	(56,154)
Treasury stock, at cost, 1,782,568 shares at April 4, 2020 and September 28, 2019	(50,282)	(50,282)
Total stockholders' deficit	(65,063)	(67,811)
Total liabilities and stockholders' deficit	$ 396,100	$ 365,413

Condensed Consolidated Balanc_2

Condensed Consolidated Balance Sheets (Parenthetical) - USD ($)	Apr. 04, 2020	Sep. 28, 2019
Statement of Financial Position [Abstract]
Preferred Stock, Par Value (in dollars per share)	$ 0.0001	$ 0.0001
Preferred Stock, Shares Authorized	10,000,000	10,000,000
Preferred Stock, Shares Issued	0	0
Preferred Stock, Liquidation Preference, Value	$ 0	$ 0
Common Stock, Par Value (in dollars per share)	$ 0.0001	$ 0.0001
Common Stock, Shares Authorized	100,000,000	100,000,000
Common Stock, Shares Outstanding	27,027,272	26,476,336
Treasury Stock, Common, Shares	1,782,568	1,782,568

Condensed Consolidated Statemen

Condensed Consolidated Statements of Operations - USD ($) $ in Thousands	3 Months Ended		6 Months Ended
	Apr. 04, 2020	Mar. 30, 2019	Apr. 04, 2020	Mar. 30, 2019
Income Statement [Abstract]
Net sales	$ 255,412	$ 211,642	$ 408,629	$ 366,568
Cost of goods sold	231,243	185,688	363,160	321,504
Gross profit	24,169	25,954	45,469	45,064
Operating expenses
Selling, general and administrative expenses	19,858	22,928	40,353	40,201
Operating profit	4,311	3,026	5,116	4,863
Interest expense	(5,658)	(3,998)	(7,555)	(6,872)
Interest income	0	0	0	9
Other income (expense), net	180	(275)	374	(624)
Loss before income taxes	(1,167)	(1,247)	(2,065)	(2,624)
Income tax benefit	817	179	1,143	415
Equity in net (loss) income of non-consolidated affiliate	(289)	395	(120)	316
Net loss	$ (639)	$ (673)	$ (1,042)	$ (1,893)
Earnings per share:
Basic weighted average shares outstanding	26,866,822	26,595,280	26,667,860	26,449,072
Diluted weighted average shares outstanding	26,866,822	26,595,280	26,667,860	26,449,072
Basic earnings per share (in dollars per share)	$ (0.02)	$ (0.03)	$ (0.04)	$ (0.07)
Diluted earnings per share (in dollars per share)	$ (0.02)	$ (0.03)	$ (0.04)	$ (0.07)

Condensed Consolidated Statem_2

Condensed Consolidated Statements of Comprehensive Income - USD ($) $ in Thousands	3 Months Ended		6 Months Ended
	Apr. 04, 2020	Mar. 30, 2019	Apr. 04, 2020	Mar. 30, 2019
Statement of Comprehensive Income [Abstract]
Net loss	$ (639)	$ (673)	$ (1,042)	$ (1,893)
Other comprehensive income, net of tax
Net change in defined benefit pension plan	326	524	653	1,048
Total other comprehensive income	326	524	653	1,048
Comprehensive loss	$ (313)	$ (149)	$ (389)	$ (845)

Condensed Consolidated Statem_3

Condensed Consolidated Statements of Cash Flows - USD ($) $ in Thousands	6 Months Ended
	Apr. 04, 2020	Mar. 30, 2019
Cash flows from operating activities
Net loss	$ (1,042)	$ (1,893)
Adjustments to reconcile net loss to net cash used in operating activities:
Depreciation and amortization	7,086	4,844
Non-cash interest expense	2,926	2,451
Share-based compensation	2,297	2,045
Equity in net loss (income) of non-consolidated affiliate	120	(316)
(Gain) loss on disposal of fixed assets	(121)	27
Deferred taxes	(291)	83
Amortization of deferred actuarial pension losses	859	1,379
Foreign currency hedges	0	109
Changes in assets and liabilities:
Accounts receivable	3,455	15,795
Inventories	(65,112)	(68,607)
Other assets	(1,350)	(3,992)
Accounts payable	17,782	16,378
Accrued expenses, pension and other liabilities	(14,818)	4,925
Total adjustments	(47,167)	(24,879)
Total cash used in operating activities	(48,209)	(26,772)
Cash flows from investing activities
Cash paid for fixed assets	(14,251)	(22,706)
Proceeds from sale of fixed assets	150	0
Total cash used in investing activities	(14,101)	(22,706)
Cash flows from financing activities
Borrowings under the revolving credit facility	30,000	20,000
Borrowings under the senior term loan	0	50,000
Repayments under the senior term loan	(4,950)	(4,950)
Principal payments on finance leases	(540)	0
Cash paid for employee taxes on vested restricted shares and stock option exercises	(3,313)	(602)
Proceeds from exercises of warrants	4,240	740
Tender offer repurchase of common stock and preferred stock	0	(50,370)
Total cash provided by financing activities	25,437	14,818
Change in cash and cash equivalents	(36,873)	(34,660)
Cash and cash equivalents, beginning of period	70,959	60,260
Cash and cash equivalents, end of period	34,086	25,600
Supplemental disclosures of cash flow information
Interest paid, net of interest received	4,807	5,055
Income tax paid, net of tax refunds	327	2,325
Non-cash investing and financing activities:
Changes in accounts payable for capital additions to property, plant and equipment	(4,041)	1,728
Cashless exercise of stock options	5,246	42
Cashless exercise of stock options	0	555
Right-of-use assets obtained in exchange for finance lease obligations	1,942	0
Right-of-use assets obtained in exchange for operating lease obligations	0	8,040
Conversion of preferred stock into common stock	$ 0	$ 9,264

Consolidated Statement of Stock

Consolidated Statement of Stockholders' Deficit Statement - USD ($) $ in Thousands	Total	Common Stock	Additional Paid-In-Capital	Convertible Preferred Stock	Accumulated Other Comprehensive Loss	Accumulated Deficit	Treasury Stock
Beginning Balance (in shares) at Sep. 29, 2018		27,259,262		93,000			0
Beginning Balance at Sep. 29, 2018	$ (28,336)	$ 3	$ 70,023	$ 9,300	$ (38,427)	$ (69,235)	$ 0
Warrant exercises (in shares)		112,635
Warrant exercises	1,295		1,295
Restricted stock activity (in shares)		51,195
Restricted stock activity	(596)		(596)
Stock option activity (in shares)		524
Stock option activity	(6)		(6)
Share-based compensation expense	1,982		1,982
Tender offer share repurchases (in shares)		1,782,568		364			1,782,568
Tender offer share repurchases	(50,370)		(73)	$ (36)			$ (50,261)
Preferred stock conversion (in shares)		799,615		92,636
Preferred stock conversion	0		9,264	$ (9,264)
Net loss	(1,893)					(1,893)
Other comprehensive income, net of tax	1,048				1,048
Ending Balance (in shares) at Mar. 30, 2019		26,440,663		0			1,782,568
Ending Balance at Mar. 30, 2019	(77,590)	$ 3	81,889	$ 0	(37,379)	(71,842)	$ (50,261)
Beginning Balance (in shares) at Dec. 29, 2018		26,351,588		0			1,782,568
Beginning Balance at Dec. 29, 2018	(79,711)	$ 3	80,433	$ 0	(38,717)	(71,169)	$ (50,261)
Warrant exercises (in shares)		58,200
Warrant exercises	675		675
Restricted stock activity (in shares)		30,682
Restricted stock activity	(357)		(357)
Stock option activity (in shares)		193
Stock option activity	(2)		(2)
Share-based compensation expense	1,161		1,161
Tender offer share repurchases	(21)		(21)
Net loss	(673)					(673)
Other comprehensive income, net of tax	524
Other comprehensive income, net of tax	1,338				1,338
Ending Balance (in shares) at Mar. 30, 2019		26,440,663		0			1,782,568
Ending Balance at Mar. 30, 2019	(77,590)	$ 3	81,889	$ 0	(37,379)	(71,842)	$ (50,261)
Beginning Balance (in shares) at Sep. 28, 2019		26,476,336		0			1,782,568
Beginning Balance at Sep. 28, 2019	(67,811)	$ 3	84,271	$ 0	(56,154)	(45,649)	$ (50,282)
Warrant exercises (in shares)		368,712
Warrant exercises	4,240		4,240
Restricted stock activity (in shares)		73,592
Restricted stock activity	(1,368)		(1,368)
Stock option activity (in shares)		108,632
Stock option activity	(1,945)		(1,945)
Share-based compensation expense	2,210		2,210
Net loss	(1,042)					(1,042)
Other comprehensive income, net of tax	653				653
Ending Balance (in shares) at Apr. 04, 2020		27,027,272		0			1,782,568
Ending Balance at Apr. 04, 2020	(65,063)	$ 3	87,408	$ 0	(55,501)	(46,691)	$ (50,282)
Beginning Balance (in shares) at Jan. 04, 2020		26,511,641		0			1,782,568
Beginning Balance at Jan. 04, 2020	(67,856)	$ 3	84,302	$ 0	(55,827)	(46,052)	$ (50,282)
Warrant exercises (in shares)		336,391
Warrant exercises	3,868		3,868
Restricted stock activity (in shares)		108,563
Restricted stock activity	0
Stock option activity (in shares)		70,677
Stock option activity	(1,935)		(1,935)
Share-based compensation expense	1,173		1,173
Net loss	(639)					(639)
Other comprehensive income, net of tax	326				326
Ending Balance (in shares) at Apr. 04, 2020		27,027,272		0			1,782,568
Ending Balance at Apr. 04, 2020	$ (65,063)	$ 3	$ 87,408	$ 0	$ (55,501)	$ (46,691)	$ (50,282)

Nature of Business and Basis of

Nature of Business and Basis of Presentation	6 Months Ended
	Apr. 04, 2020
Organization, Consolidation and Presentation of Financial Statements [Abstract]
Nature of Business and Basis of Presentation	1. Nature of Business and Basis of Presentation Nature of Business Blue Bird Body Company, a wholly-owned subsidiary of Blue Bird Corporation, was incorporated in 1958 and has manufactured, assembled and sold school buses to a variety of municipal, federal and commercial customers since 1927. The majority of Blue Bird’s sales are made to an independent distributor network, which in turn sells buses to ultimate end users. We are headquartered in Macon, Georgia. References in these notes to financial statements to “Blue Bird”, the “Company,” “we,” “our,” or “us” refer to Blue Bird Corporation and its wholly-owned subsidiaries, unless the context specifically indicates otherwise. COVID-19 During our second fiscal quarter of 2020, the novel coronavirus known as "COVID-19" spread throughout the world creating a global pandemic. The COVID-19 pandemic did not materially impact our second fiscal quarter of 2020 financial condition, results of operations, or liquidity. The full extent of the future impacts of COVID-19 on the Company's operations is uncertain. A prolonged economic shutdown could have a material adverse impact on our financial results. For further discussion about COVID-19, please refer to Part I, Item 2. "Management’s Discussion and Analysis of Financial Condition and Results of Operations" and Part II, Item 1A. "Risk Factors" of this Quarterly Report on Form 10-Q. Basis of Presentation The accompanying unaudited condensed consolidated financial statements include the accounts of the Company and its wholly-owned subsidiaries. All significant inter-company transactions and accounts have been eliminated in consolidation. The accompanying unaudited condensed consolidated financial statements have been prepared in accordance with generally accepted accounting principles for interim financial reporting and Article 8 of Regulation S-X. The Company’s fiscal year ends on the Saturday closest to September 30 with its quarters consisting of thirteen weeks in most years. In fiscal year 2020 , there is a total of 53 weeks. The second quarters of fiscal 2020 and 2019 both included 13 weeks. The six month periods in fiscal 2020 and 2019 included 27 and 26 weeks, respectively. In the opinion of management, all adjustments considered necessary for a fair presentation of financial results have been made. Such adjustments consist of only those of a normal recurring nature. Operating results for any interim period are not necessarily indicative of the results that may be expected for the entire year. Accordingly, they do not include all of the information and footnotes required by generally accepted accounting principles for complete financial statements. The Condensed Consolidated Balance Sheet data as of September 28, 2019 was derived from the Company’s audited financial statements but does not include all disclosures required by generally accepted accounting principles. For additional information, including the Company’s significant accounting policies, refer to the consolidated financial statements and related footnotes for the fiscal year ended September 28, 2019 as set forth in the Company's 2019 Form 10-K filed on December 12, 2019 . Use of Estimates and Assumptions The preparation of financial statements in accordance with accounting principles generally accepted in the United States of America (“U.S. GAAP”) requires management to make estimates and assumptions. At the date of the financial statements, these estimates and assumptions affect the reported amounts of assets and liabilities and disclosures of contingent assets and liabilities, and during the reporting period, these estimates and assumptions affect the reported amounts of revenues and expenses. For example, significant management judgments are required in determining excess, obsolete, or unsalable inventory, allowance for doubtful accounts, potential impairment of long-lived assets, goodwill and intangibles, the accounting for self-insurance reserves, warranty reserves, pension obligations, income taxes, environmental liabilities and contingencies. Future events, including the extent and duration of COVID-19 related economic impacts, and their effects cannot be predicted with certainty, and, accordingly, the Company’s accounting estimates require the exercise of judgment. The accounting estimates used in the preparation of the Company’s condensed consolidated financial statements may change as new events occur, as more experience is acquired, as additional information is obtained and as the Company’s operating environment changes. The Company evaluates and updates its assumptions and estimates on an ongoing basis and may employ outside experts to assist in the Company’s evaluations. Actual results could differ from the estimates that the Company has used.

Summary of Significant Accounti

Summary of Significant Accounting Policies and Recently Issued Accounting Standards	6 Months Ended
	Apr. 04, 2020
Accounting Policies [Abstract]
Summary of Significant Accounting Policies and Recently Issued Accounting Standards	2. Summary of Significant Accounting Policies and Recently Issued Accounting Standards The Company’s significant accounting policies are described in the Company’s 2019 Form 10-K, filed with the SEC on December 12, 2019 . Our senior management has reviewed these significant accounting policies and related disclosures and determined that there were no significant changes in our critical accounting policies in the six months ended April 4, 2020 , except as follows (and as discussed in the Recently Adopted Accounting Standards section of this Note 2 ): Amortization of Deferred Pension Losses Historically, the Company has amortized deferred losses from our frozen defined benefit pension plan accounted for under ASC 715, Compensation - Retirement Benefits, over the expected remaining employment period of the participants who remained employed with the Company. ASC 715 states that if all or almost all of a plan's participants are inactive, the average remaining life expectancy of the inactive participants shall be used to amortize the unrecognized net gain or loss instead of the average remaining service period of active plan participants. In the first quarter of 2020, the ratio of active (employed) to inactive participants in our plan declined to less than 10% , a figure we believe meets the definition of almost all participants as inactive. Accordingly, we have changed the amortization period from approximately seven years in 2019 to approximately 23 years in 2020. Future amortization periods (remaining life expectancy) will be determined based on the participant and actuarial data at that time . Recently Adopted Accounting Standards ASU 2018-02 – In February 2018, the FASB issued ASU No. 2018-02, Income Statement - Reporting Comprehensive Income (Topic 220) . This ASU provides guidance on a reclassification from accumulated other comprehensive income ("AOCI") to retained earnings for the effect of the tax rate change resulting from the Tax Cuts and Jobs Act (H.R.1) (the "Tax Act"). The amendments eliminate the stranded tax effects resulting from the Tax Act and will improve the usefulness of information reported to financial statement users. This ASU is effective for fiscal years, and interim periods within those fiscal years, beginning after December 15, 2018, with early adoption permitted. We adopted this ASU, in the first quarter of fiscal 2020, and did not elect to reclassify the income tax effects of the Tax Act from AOCI to retained earnings. We use a specific identification approach to release the income tax effects in AOCI. ASU 2019-12 – In December 2019, the FASB issued ASU No. 2019-12, Simplifying the Accounting for Income Taxes , which simplifies the process for calculating interim (intraperiod) income taxes and the accounting for deferred tax liabilities for foreign equity-method investments, among other simplifications. We have early adopted this standard effective the first quarter of fiscal 2020. The impacts of adopting this standard were not material to us. Recently Issued Accounting Standards ASU 2020-04 – On March 12, 2020, the FASB issued ASU 2020-04, Reference Rate Reform (Topic 848): Facilitation of the Effects of Reference Rate Reform on Financial Reporting, providing temporary guidance to ease the potential burden in accounting for reference rate reform primarily resulting from the discontinuation of LIBOR, which is currently expected to occur on December 31, 2021. The amendments in ASU 2020-04 are elective and apply to all entities that have contracts, hedging relationships, and other transactions that reference LIBOR or another reference rate expected to be discontinued. An entity may elect to apply the amendments prospectively from March 12, 2020 through December 31, 2022. Our debt and derivative agreements currently reference LIBOR. Contract language is expected to be incorporated into these agreements to address the transition to an alternative rate. We are currently evaluating the impact this ASU may have on our consolidated financial statements.

Supplemental Financial Informat

Supplemental Financial Information	6 Months Ended
	Apr. 04, 2020
Condensed Financial Information [Abstract]
Supplemental Financial Information	3. Supplemental Financial Information Inventories The following table presents the components of inventories at the dates indicated: (in thousands of dollars) April 4, 2020 September 28, 2019 Raw materials $ 116,386 $ 60,033 Work in process 18,089 16,663 Finished goods 9,467 2,134 Total inventories $ 143,942 $ 78,830 Product Warranties The following table reflects activity in accrued warranty cost (current and long-term portions combined) for the periods presented: Three Months Ended Six Months Ended (in thousands of dollars) April 4, 2020 March 30, 2019 April 4, 2020 March 30, 2019 Balance at beginning of period $ 21,731 $ 21,858 $ 22,343 $ 22,646 Add current period accruals 2,628 2,248 4,129 3,838 Current period reductions of accrual (2,961 ) (2,586 ) (5,074 ) (4,964 ) Balance at end of period $ 21,398 $ 21,520 $ 21,398 $ 21,520 Extended Warranties The following table reflects activity in deferred warranty income (current and long-term portions combined), for the sale of extended warranties of two to five years , for the periods presented: Three Months Ended Six Months Ended (in thousands of dollars) April 4, 2020 March 30, 2019 April 4, 2020 March 30, 2019 Balance at beginning of period $ 22,744 $ 22,532 $ 24,045 $ 23,191 Add current period deferred income 2,338 2,440 3,289 3,806 Current period recognition of income (2,134 ) (2,071 ) (4,386 ) (4,096 ) Balance at end of period $ 22,948 $ 22,901 $ 22,948 $ 22,901 The outstanding balance of deferred warranty income in the table above is considered a "contract liability", and represents a performance obligation of the Company that we satisfy over the term of the arrangement but for which we have been paid in full at the time the warranty was sold. We expect to recognize $4.5 million of the outstanding contract liability during the remainder of fiscal 2020 , $7.4 million in fiscal 2021 , and the remaining balance thereafter. Self-Insurance The following table reflects our total accrued self-insurance liability, comprised of workers' compensation and health insurance related claims, at the dates indicated: (in thousands of dollars) April 4, 2020 September 28, 2019 Current portion $ 3,120 $ 2,933 Long-term portion 1,935 1,775 Total accrued self-insurance $ 5,055 $ 4,708 The current and long-term portions of the accrued self-insurance liability are reflected in accrued expenses and other liabilities, respectively, on the Condensed Consolidated Balance Sheets. Shipping and Handling Revenues Shipping and handling revenues were $4.1 million and $3.2 million for the three months ended April 4, 2020 and March 30, 2019 , respectively, and $7.6 million and $6.5 million for the six months ended April 4, 2020 and March 30, 2019 , respectively. The related cost of goods sold was $3.5 million and $2.7 million for the three months ended April 4, 2020 and March 30, 2019 , respectively, and $6.6 million and $5.7 million for the six months ended April 4, 2020 and March 30, 2019 , respectively. Pension Expense Components of net periodic pension benefit cost were as follows for the periods presented: Three Months Ended Six Months Ended (in thousands of dollars) April 4, 2020 March 30, 2019 April 4, 2020 March 30, 2019 Interest cost $ 1,237 $ 1,511 $ 2,474 $ 3,023 Expected return on plan assets (1,846 ) (1,904 ) (3,692 ) (3,809 ) Amortization of prior loss 429 690 859 1,379 Net periodic benefit cost $ (180 ) $ 297 $ (359 ) $ 593 Amortization of prior loss, recognized in other comprehensive income 429 690 859 1,379 Total recognized in net periodic pension benefit cost and other comprehensive income $ (609 ) $ (393 ) $ (1,218 ) $ (786 ) Derivative Instruments We are charged variable rates of interest on our indebtedness outstanding under the Amended Credit Agreement (defined below) which exposes us to fluctuations in interest rates. On October 24, 2018, the Company entered into a four -year interest rate collar with a $150.0 million notional value with an effective date of November 30, 2018. The collar was entered into in order to partially mitigate our exposure to interest rate fluctuations on our variable rate debt. The collar establishes a range where we will pay the counterparty if the three-month LIBOR rate falls below the established floor rate of 1.5% , and the counterparty will pay us if the three-month LIBOR rate exceeds the ceiling rate of 3.3% . The collar settles quarterly through the termination date of September 30, 2022. No payments or receipts are exchanged on the interest rate collar contracts unless interest rates rise above or fall below the contracted ceiling or floor rates. Changes in the interest rate collar fair value are recorded in interest expense as the collar does not qualify for hedge accounting. At April 4, 2020 , the fair value of the interest rate collar contract was $(3.4) million and is included in "other current liabilities" on the Condensed Consolidated Balance Sheets. The fair value of the interest rate collar is a Level 2 fair value measurement, based on quoted prices of similar items in active markets.

Debt

Debt	6 Months Ended
	Apr. 04, 2020
Debt Disclosure [Abstract]
Debt	4. Debt Term debt consisted of the following at the dates indicated: (in thousands of dollars) April 4, 2020 September 28, 2019 2023 term loan, net of deferred financing costs of $2,685 and $3,124, respectively $ 178,615 $ 183,126 Less: current portion of long-term debt 9,900 9,900 Long-term debt, net of current portion $ 168,715 $ 173,226 Term loans are recognized on the Condensed Consolidated Balance Sheets at the unpaid principal balance, and are not subject to fair value measurement; however, given the variable rates on the loans, the Company estimates that the unpaid principal balance approximates fair value. If measured at fair value in the financial statements, the term loans would be classified as Level 2 in the fair value hierarchy. At April 4, 2020 and September 28, 2019 , $181.3 million and $186.3 million , respectively, were outstanding on the term loans. At April 4, 2020 and September 28, 2019 , the stated interest rates on the term loans were 3.2% and 4.4% , respectively. At April 4, 2020 and September 28, 2019 , the weighted-average annual effective interest rates for the term loans were 4.5% and 5.0% , respectively, which includes amortization of the deferred financing costs. At April 4, 2020 , $30.0 million in borrowings were outstanding on the Revolving Credit Facility and $6.9 million of Letters of Credit were outstanding; therefore, the Company would have been able to borrow $63.1 million on the revolving line of credit. Interest expense on all indebtedness was $5.7 million and $4.0 million for the three months ended April 4, 2020 and March 30, 2019 , respectively, and $7.6 million and $6.9 million for the six months ended April 4, 2020 and March 30, 2019 , respectively. The schedule of remaining principal payments through maturity for total debt is as follows: (in thousands of dollars) Year Principal Payments 2020 $ 4,950 2021 9,900 2022 14,850 2023 181,600 Total remaining principal payments $ 211,300

Income Taxes

Income Taxes	6 Months Ended
	Apr. 04, 2020
Income Tax Disclosure [Abstract]
Income Taxes	5. Income Taxes Income tax provisions for interim periods are based on estimated annual income tax rates, adjusted to reflect the effects of any significant infrequent or unusual items which are required to be discretely recognized within the current interim period. The effective tax rates in the periods presented are largely based upon the forecast pre-tax earnings mix and allocation of certain expenses in various taxing jurisdictions where the Company conducts its business, primarily the United States. In periods where our operating income approximates or is equal to break-even, the effective tax rates for quarter-to-date and full-year periods may not be meaningful due to discrete period items. On March 27, 2020 the President of the United States signed the Coronavirus Aid, Relief and Economic Security Act ("CARES Act") into law. While the CARES Act has broad income tax implications for many companies, it did not have a material impact on our reported income tax accounts. Three Months The effective tax rate for the three-month period ended April 4, 2020 was 70.0% , which differed from the statutory federal income tax rate of 21% . The difference is mainly due to discrete period tax benefit from share-based compensation expenses, but also due to normal tax rate items, such as the benefit from federal and state tax credits (net of valuation allowance), which were partially offset by net non-deductible compensation expenses and other tax adjustments. The effective tax rate for the three-month period ended March 30, 2019 was 14.4% , which differed from the statutory federal tax rate of 21% . The difference is mainly due to normal tax rate benefit items, such as federal and state tax credits (net of valuation allowance), which were partially offset by non-deductible share-based compensation expenses and other tax adjustments. Six Months The effective tax rate for the six -month period ended April 4, 2020 was 55.4% and differed from the statutory federal tax rate of 21% . The difference is mainly due to discrete period tax benefit from share-based compensation expenses, but also due to normal tax rate items, such as the benefit from federal and state tax credits (net of valuation allowance), which were partially offset by net non-deductible compensation expenses and other tax adjustments. The effective tax rate for the six -month period ended March 30, 2019 was 15.8% and differed from the statutory federal income tax rate of 21% . The difference is mainly due to normal tax rate benefit items, primarily federal and state tax credits (net of valuation allowance), which were partially offset by non-deductible share-based compensation expenses and other tax adjustments.

Guarantees, Commitments and Con

Guarantees, Commitments and Contingencies	6 Months Ended
	Apr. 04, 2020
Commitments and Contingencies Disclosure [Abstract]
Guarantees, Commitments and Contingencies	6. Guarantees, Commitments and Contingencies Litigation At April 4, 2020 , the Company had a number of product liability and other cases pending. Management believes that, considering the Company’s insurance coverage and its intention to vigorously defend its positions, the ultimate resolution of these matters will not have a material adverse effect on the Company’s financial statements. Environmental The Company is subject to a variety of environmental regulations relating to the use, storage, discharge and disposal of hazardous materials used in its manufacturing processes. Failure by the Company to comply with present and future regulations could subject it to future liabilities. In addition, such regulations could require the Company to acquire costly equipment or to incur other significant expenses to comply with environmental regulations. The Company is currently not involved in any material environmental proceedings and therefore management believes that the resolution of pending environmental matters will not have a material adverse effect on the Company’s financial statements. Guarantees In the ordinary course of business, we may provide guarantees for certain transactions entered into by our dealers. At April 4, 2020 , we had a $3.0 million guarantee outstanding which relates to a guarantee of indebtedness for a term loan with remaining maturity up to 2.8 years . The $3.0 million represents the estimated maximum amount we would be required to pay upon default of all guaranteed indebtedness, and we believe the likelihood of required performance to be remote. At April 4, 2020 , $0.3 million was included in other current liabilities on our Condensed Consolidated Balance Sheets for the estimated fair value of the guarantee. Lease Commitments We have operating and finance leases for office and/or warehouse space and for equipment. Our leases have remaining terms of 4.7 to 7.7 years .

Segment Information

Segment Information	6 Months Ended
	Apr. 04, 2020
Segment Reporting [Abstract]
Segment Information	7. Segment Information We manage our business in two operating segments: (i) the Bus segment, which includes the manufacturing and assembly of buses to be sold to a variety of customers across the United States, Canada and in international markets; and (ii) the Parts segment, which consists primarily of the purchase of parts from third parties to be sold to dealers within the Company’s network. The tables below present segment net sales and gross profit for the periods presented: Net sales Three Months Ended Six Months Ended (in thousands of dollars) April 4, 2020 March 30, 2019 April 4, 2020 March 30, 2019 Bus (1) $ 238,697 $ 195,065 $ 373,469 $ 334,275 Parts (1) 16,715 16,577 35,160 32,293 Segment net sales $ 255,412 $ 211,642 $ 408,629 $ 366,568 (1) Parts segment revenue includes $1.2 million and $0.9 million for the three months ended April 4, 2020 and March 30, 2019 , respectively, and $2.4 million and $1.5 million for the six months ended April 4, 2020 and March 30, 2019 , respectively, related to inter-segment sales of parts that was eliminated by the Bus segment upon consolidation. Gross profit Three Months Ended Six Months Ended (in thousands of dollars) April 4, 2020 March 30, 2019 April 4, 2020 March 30, 2019 Bus $ 17,938 $ 20,142 $ 32,805 $ 33,657 Parts 6,231 5,812 12,664 11,407 Segment gross profit $ 24,169 $ 25,954 $ 45,469 $ 45,064 The following table is a reconciliation of segment gross profit to consolidated loss before income taxes for the periods presented: Three Months Ended Six Months Ended (in thousands of dollars) April 4, 2020 March 30, 2019 April 4, 2020 March 30, 2019 Segment gross profit $ 24,169 $ 25,954 $ 45,469 $ 45,064 Adjustments: Selling, general and administrative expenses (19,858 ) (22,928 ) (40,353 ) (40,201 ) Interest expense (5,658 ) (3,998 ) (7,555 ) (6,872 ) Interest income — — — 9 Other income (expense), net 180 (275 ) 374 (624 ) Loss before income taxes $ (1,167 ) $ (1,247 ) $ (2,065 ) $ (2,624 ) Sales are attributable to geographic areas based on customer location and were as follows for the periods presented: Three Months Ended Six Months Ended (in thousands of dollars) April 4, 2020 March 30, 2019 April 4, 2020 March 30, 2019 United States $ 232,477 $ 191,684 $ 368,743 $ 343,169 Canada 22,746 18,784 35,902 21,860 Rest of world 189 1,174 3,984 1,539 Total net sales $ 255,412 $ 211,642 $ 408,629 $ 366,568

Revenue

Revenue	6 Months Ended
	Apr. 04, 2020
Revenue from Contract with Customer [Abstract]
Revenue from Contract with Customer	8. Revenue The following table disaggregates revenue by product category for the periods presented: Three Months Ended Six Months Ended (in thousands of dollars) April 4, 2020 March 30, 2019 April 4, 2020 March 30, 2019 Diesel buses $ 113,649 $ 110,487 $ 190,399 $ 200,307 Alternative fuel buses (1) 113,057 75,320 164,791 118,401 Other (2) 12,505 9,773 19,348 16,575 Parts 16,201 16,062 34,091 31,285 Net sales $ 255,412 $ 211,642 $ 408,629 $ 366,568 (1) Includes buses sold with any fuel source other than diesel (e.g. gasoline, propane, CNG, electric). (2) Includes shipping and handling revenue, extended warranty income, surcharges, chassis, and bus shell sales.

Earnings Per Share

Earnings Per Share	6 Months Ended
	Apr. 04, 2020
Earnings Per Share [Abstract]
Earnings Per Share	9. Earnings Per Share The following table presents the earnings per share computation for the periods presented: Three Months Ended Six Months Ended (in thousands except for share data) April 4, 2020 March 30, 2019 April 4, 2020 March 30, 2019 Numerator: Net loss $ (639 ) $ (673 ) $ (1,042 ) $ (1,893 ) Denominator: Weighted-average common shares outstanding 26,866,822 26,595,280 26,667,860 26,449,072 Effect of dilutive securities (1) — — — — Weighted-average shares and dilutive potential common shares 26,866,822 26,595,280 26,667,860 26,449,072 Earnings per share: Basic loss per share $ (0.02 ) $ (0.03 ) $ (0.04 ) $ (0.07 ) Diluted loss per share $ (0.02 ) $ (0.03 ) $ (0.04 ) $ (0.07 ) (1) Potentially dilutive securities representing 0.5 million and 1.4 million shares of common stock were excluded from the computation of diluted earnings per share for April 4, 2020 and March 30, 2019 , respectively, as their effect would have been antidilutive.

Accumulated Other Comprehensive

Accumulated Other Comprehensive Loss	6 Months Ended
	Apr. 04, 2020
Equity [Abstract]
Accumulated Other Comprehensive Loss	10. Accumulated Other Comprehensive Loss The following table provides information on changes in accumulated other comprehensive loss for the periods presented: Three Months Ended Six Months Ended (in thousands of dollars) Defined Benefit Pension Plan Total Defined Benefit Pension Plan Total April 4, 2020 Beginning Balance $ (55,827 ) $ (55,827 ) $ (56,154 ) $ (56,154 ) Amounts reclassified from other comprehensive loss and included in earnings 429 429 859 859 Total other comprehensive income, before taxes 429 429 859 859 Income tax expense (103 ) (103 ) (206 ) (206 ) Ending Balance April 4, 2020 $ (55,501 ) $ (55,501 ) $ (55,501 ) $ (55,501 ) March 30, 2019 Beginning Balance $ (37,903 ) $ (37,903 ) $ (38,427 ) $ (38,427 ) Amounts reclassified from other comprehensive loss and included in earnings 690 690 1,379 1,379 Total other comprehensive income, before taxes 690 690 1,379 1,379 Income tax expense (166 ) (166 ) (331 ) (331 ) Ending Balance March 30, 2019 $ (37,379 ) $ (37,379 ) $ (37,379 ) $ (37,379 )

Subsequent Event

Subsequent Event	6 Months Ended
	Apr. 04, 2020
Subsequent Events [Abstract]
Subsequent Event	11. Subsequent Event Second Amendment to the Credit Agreement As reported in our May 8, 2020 Current Report on Form 8-K, on May 7, 2020, the Company entered into a Second Amendment which amended the Credit Agreement, dated as of December 12, 2016 (the “Credit Agreement”, as amended by that certain First Amendment to Credit Agreement, dated as of September 13, 2018 (the “First Amendment”), and as further amended by the Second Amendment, the “Amended Credit Agreement”). The Second Amendment, among other things, provides for an aggregate lender commitment of $41.9 million of additional revolving commitments bringing the total revolving commitments to $141.9 million . The additional revolving commitments are intended to be used for working capital, to fund general corporate purposes and to pay transaction costs, fees and expenses related thereto and in connection with the Second Amendment. The revolving commitments under the Amended Credit Agreement will mature on September 13, 2023, which is the fifth anniversary of the effective date of the First Amendment. The interest rate pricing grid remained unchanged, but the LIBOR floor was amended from 0% to 0.75% . Approximately $0.9 million in fees were incurred related to the amendment and are expected to be capitalized.

Nature of Business and Basis _2

Nature of Business and Basis of Presentation (Policies)	6 Months Ended
	Apr. 04, 2020
Organization, Consolidation and Presentation of Financial Statements [Abstract]
Basis of Presentation	Basis of Presentation The accompanying unaudited condensed consolidated financial statements include the accounts of the Company and its wholly-owned subsidiaries. All significant inter-company transactions and accounts have been eliminated in consolidation. The accompanying unaudited condensed consolidated financial statements have been prepared in accordance with generally accepted accounting principles for interim financial reporting and Article 8 of Regulation S-X. The Company’s fiscal year ends on the Saturday closest to September 30 with its quarters consisting of thirteen weeks in most years. In fiscal year 2020 , there is a total of 53 weeks. The second quarters of fiscal 2020 and 2019 both included 13 weeks. The six month periods in fiscal 2020 and 2019 included 27 and 26 weeks, respectively. In the opinion of management, all adjustments considered necessary for a fair presentation of financial results have been made. Such adjustments consist of only those of a normal recurring nature. Operating results for any interim period are not necessarily indicative of the results that may be expected for the entire year. Accordingly, they do not include all of the information and footnotes required by generally accepted accounting principles for complete financial statements. The Condensed Consolidated Balance Sheet data as of September 28, 2019 was derived from the Company’s audited financial statements but does not include all disclosures required by generally accepted accounting principles. For additional information, including the Company’s significant accounting policies, refer to the consolidated financial statements and related footnotes for the fiscal year ended September 28, 2019 as set forth in the Company's 2019 Form 10-K filed on December 12, 2019 .
Use of Estimates and Assumptions	Use of Estimates and Assumptions The preparation of financial statements in accordance with accounting principles generally accepted in the United States of America (“U.S. GAAP”) requires management to make estimates and assumptions. At the date of the financial statements, these estimates and assumptions affect the reported amounts of assets and liabilities and disclosures of contingent assets and liabilities, and during the reporting period, these estimates and assumptions affect the reported amounts of revenues and expenses. For example, significant management judgments are required in determining excess, obsolete, or unsalable inventory, allowance for doubtful accounts, potential impairment of long-lived assets, goodwill and intangibles, the accounting for self-insurance reserves, warranty reserves, pension obligations, income taxes, environmental liabilities and contingencies. Future events, including the extent and duration of COVID-19 related economic impacts, and their effects cannot be predicted with certainty, and, accordingly, the Company’s accounting estimates require the exercise of judgment. The accounting estimates used in the preparation of the Company’s condensed consolidated financial statements may change as new events occur, as more experience is acquired, as additional information is obtained and as the Company’s operating environment changes. The Company evaluates and updates its assumptions and estimates on an ongoing basis and may employ outside experts to assist in the Company’s evaluations. Actual results could differ from the estimates that the Company has used.
Amortization of Deferred Pension Losses	Amortization of Deferred Pension Losses Historically, the Company has amortized deferred losses from our frozen defined benefit pension plan accounted for under ASC 715, Compensation - Retirement Benefits, over the expected remaining employment period of the participants who remained employed with the Company. ASC 715 states that if all or almost all of a plan's participants are inactive, the average remaining life expectancy of the inactive participants shall be used to amortize the unrecognized net gain or loss instead of the average remaining service period of active plan participants. In the first quarter of 2020, the ratio of active (employed) to inactive participants in our plan declined to less than 10% , a figure we believe meets the definition of almost all participants as inactive. Accordingly, we have changed the amortization period from approximately seven years in 2019 to approximately 23 years in 2020. Future amortization periods (remaining life expectancy) will be determined based on the participant and actuarial data at that time .
Recently Issued Accounting Standards and Recently Adopted Accounting Standards	Recently Adopted Accounting Standards ASU 2018-02 – In February 2018, the FASB issued ASU No. 2018-02, Income Statement - Reporting Comprehensive Income (Topic 220) . This ASU provides guidance on a reclassification from accumulated other comprehensive income ("AOCI") to retained earnings for the effect of the tax rate change resulting from the Tax Cuts and Jobs Act (H.R.1) (the "Tax Act"). The amendments eliminate the stranded tax effects resulting from the Tax Act and will improve the usefulness of information reported to financial statement users. This ASU is effective for fiscal years, and interim periods within those fiscal years, beginning after December 15, 2018, with early adoption permitted. We adopted this ASU, in the first quarter of fiscal 2020, and did not elect to reclassify the income tax effects of the Tax Act from AOCI to retained earnings. We use a specific identification approach to release the income tax effects in AOCI. ASU 2019-12 – In December 2019, the FASB issued ASU No. 2019-12, Simplifying the Accounting for Income Taxes , which simplifies the process for calculating interim (intraperiod) income taxes and the accounting for deferred tax liabilities for foreign equity-method investments, among other simplifications. We have early adopted this standard effective the first quarter of fiscal 2020. The impacts of adopting this standard were not material to us. Recently Issued Accounting Standards ASU 2020-04 – On March 12, 2020, the FASB issued ASU 2020-04, Reference Rate Reform (Topic 848): Facilitation of the Effects of Reference Rate Reform on Financial Reporting, providing temporary guidance to ease the potential burden in accounting for reference rate reform primarily resulting from the discontinuation of LIBOR, which is currently expected to occur on December 31, 2021. The amendments in ASU 2020-04 are elective and apply to all entities that have contracts, hedging relationships, and other transactions that reference LIBOR or another reference rate expected to be discontinued. An entity may elect to apply the amendments prospectively from March 12, 2020 through December 31, 2022. Our debt and derivative agreements currently reference LIBOR. Contract language is expected to be incorporated into these agreements to address the transition to an alternative rate. We are currently evaluating the impact this ASU may have on our consolidated financial statements.

Supplemental Financial Inform_2

Supplemental Financial Information (Tables)	6 Months Ended
	Apr. 04, 2020
Condensed Financial Information [Abstract]
Inventories	The following table presents the components of inventories at the dates indicated: (in thousands of dollars) April 4, 2020 September 28, 2019 Raw materials $ 116,386 $ 60,033 Work in process 18,089 16,663 Finished goods 9,467 2,134 Total inventories $ 143,942 $ 78,830
Product Warranties	The following table reflects activity in accrued warranty cost (current and long-term portions combined) for the periods presented: Three Months Ended Six Months Ended (in thousands of dollars) April 4, 2020 March 30, 2019 April 4, 2020 March 30, 2019 Balance at beginning of period $ 21,731 $ 21,858 $ 22,343 $ 22,646 Add current period accruals 2,628 2,248 4,129 3,838 Current period reductions of accrual (2,961 ) (2,586 ) (5,074 ) (4,964 ) Balance at end of period $ 21,398 $ 21,520 $ 21,398 $ 21,520 Extended Warranties The following table reflects activity in deferred warranty income (current and long-term portions combined), for the sale of extended warranties of two to five years , for the periods presented: Three Months Ended Six Months Ended (in thousands of dollars) April 4, 2020 March 30, 2019 April 4, 2020 March 30, 2019 Balance at beginning of period $ 22,744 $ 22,532 $ 24,045 $ 23,191 Add current period deferred income 2,338 2,440 3,289 3,806 Current period recognition of income (2,134 ) (2,071 ) (4,386 ) (4,096 ) Balance at end of period $ 22,948 $ 22,901 $ 22,948 $ 22,901
Self-Insurance	The following table reflects our total accrued self-insurance liability, comprised of workers' compensation and health insurance related claims, at the dates indicated: (in thousands of dollars) April 4, 2020 September 28, 2019 Current portion $ 3,120 $ 2,933 Long-term portion 1,935 1,775 Total accrued self-insurance $ 5,055 $ 4,708
Pension Expense	Components of net periodic pension benefit cost were as follows for the periods presented: Three Months Ended Six Months Ended (in thousands of dollars) April 4, 2020 March 30, 2019 April 4, 2020 March 30, 2019 Interest cost $ 1,237 $ 1,511 $ 2,474 $ 3,023 Expected return on plan assets (1,846 ) (1,904 ) (3,692 ) (3,809 ) Amortization of prior loss 429 690 859 1,379 Net periodic benefit cost $ (180 ) $ 297 $ (359 ) $ 593 Amortization of prior loss, recognized in other comprehensive income 429 690 859 1,379 Total recognized in net periodic pension benefit cost and other comprehensive income $ (609 ) $ (393 ) $ (1,218 ) $ (786 )

Debt (Tables)

Debt (Tables)	6 Months Ended
	Apr. 04, 2020
Debt Disclosure [Abstract]
Schedule of Term Debt Instruments	Term debt consisted of the following at the dates indicated: (in thousands of dollars) April 4, 2020 September 28, 2019 2023 term loan, net of deferred financing costs of $2,685 and $3,124, respectively $ 178,615 $ 183,126 Less: current portion of long-term debt 9,900 9,900 Long-term debt, net of current portion $ 168,715 $ 173,226
Schedule of Maturities of Long-term Debt	The schedule of remaining principal payments through maturity for total debt is as follows: (in thousands of dollars) Year Principal Payments 2020 $ 4,950 2021 9,900 2022 14,850 2023 181,600 Total remaining principal payments $ 211,300

Segment Information (Tables)

Segment Information (Tables)	6 Months Ended
	Apr. 04, 2020
Segment Reporting [Abstract]
Schedule of Segment Reporting Information, by Segment	The tables below present segment net sales and gross profit for the periods presented: Net sales Three Months Ended Six Months Ended (in thousands of dollars) April 4, 2020 March 30, 2019 April 4, 2020 March 30, 2019 Bus (1) $ 238,697 $ 195,065 $ 373,469 $ 334,275 Parts (1) 16,715 16,577 35,160 32,293 Segment net sales $ 255,412 $ 211,642 $ 408,629 $ 366,568 (1) Parts segment revenue includes $1.2 million and $0.9 million for the three months ended April 4, 2020 and March 30, 2019 , respectively, and $2.4 million and $1.5 million for the six months ended April 4, 2020 and March 30, 2019 , respectively, related to inter-segment sales of parts that was eliminated by the Bus segment upon consolidation. Gross profit Three Months Ended Six Months Ended (in thousands of dollars) April 4, 2020 March 30, 2019 April 4, 2020 March 30, 2019 Bus $ 17,938 $ 20,142 $ 32,805 $ 33,657 Parts 6,231 5,812 12,664 11,407 Segment gross profit $ 24,169 $ 25,954 $ 45,469 $ 45,064
Reconciliation of Operating Profit (Loss) from Segments to Consolidated	The following table is a reconciliation of segment gross profit to consolidated loss before income taxes for the periods presented: Three Months Ended Six Months Ended (in thousands of dollars) April 4, 2020 March 30, 2019 April 4, 2020 March 30, 2019 Segment gross profit $ 24,169 $ 25,954 $ 45,469 $ 45,064 Adjustments: Selling, general and administrative expenses (19,858 ) (22,928 ) (40,353 ) (40,201 ) Interest expense (5,658 ) (3,998 ) (7,555 ) (6,872 ) Interest income — — — 9 Other income (expense), net 180 (275 ) 374 (624 ) Loss before income taxes $ (1,167 ) $ (1,247 ) $ (2,065 ) $ (2,624 )
Revenue from External Customers by Geographic Areas	Sales are attributable to geographic areas based on customer location and were as follows for the periods presented: Three Months Ended Six Months Ended (in thousands of dollars) April 4, 2020 March 30, 2019 April 4, 2020 March 30, 2019 United States $ 232,477 $ 191,684 $ 368,743 $ 343,169 Canada 22,746 18,784 35,902 21,860 Rest of world 189 1,174 3,984 1,539 Total net sales $ 255,412 $ 211,642 $ 408,629 $ 366,568

Revenue (Tables)

Revenue (Tables)	6 Months Ended
	Apr. 04, 2020
Revenue from Contract with Customer [Abstract]
Disaggregation of Revenue	The following table disaggregates revenue by product category for the periods presented: Three Months Ended Six Months Ended (in thousands of dollars) April 4, 2020 March 30, 2019 April 4, 2020 March 30, 2019 Diesel buses $ 113,649 $ 110,487 $ 190,399 $ 200,307 Alternative fuel buses (1) 113,057 75,320 164,791 118,401 Other (2) 12,505 9,773 19,348 16,575 Parts 16,201 16,062 34,091 31,285 Net sales $ 255,412 $ 211,642 $ 408,629 $ 366,568 (1) Includes buses sold with any fuel source other than diesel (e.g. gasoline, propane, CNG, electric). (2) Includes shipping and handling revenue, extended warranty income, surcharges, chassis, and bus shell sales

Earnings Per Share (Tables)

Earnings Per Share (Tables)	6 Months Ended
	Apr. 04, 2020
Earnings Per Share [Abstract]
Schedule of Earnings Per Share, Basic and Diluted	The following table presents the earnings per share computation for the periods presented: Three Months Ended Six Months Ended (in thousands except for share data) April 4, 2020 March 30, 2019 April 4, 2020 March 30, 2019 Numerator: Net loss $ (639 ) $ (673 ) $ (1,042 ) $ (1,893 ) Denominator: Weighted-average common shares outstanding 26,866,822 26,595,280 26,667,860 26,449,072 Effect of dilutive securities (1) — — — — Weighted-average shares and dilutive potential common shares 26,866,822 26,595,280 26,667,860 26,449,072 Earnings per share: Basic loss per share $ (0.02 ) $ (0.03 ) $ (0.04 ) $ (0.07 ) Diluted loss per share $ (0.02 ) $ (0.03 ) $ (0.04 ) $ (0.07 ) (1) Potentially dilutive securities representing 0.5 million and 1.4 million shares of common stock were excluded from the computation of diluted earnings per share for April 4, 2020 and March 30, 2019 , respectively, as their effect would have been antidilutive.

Accumulated Other Comprehensi_2

Accumulated Other Comprehensive Loss (Tables)	6 Months Ended
	Apr. 04, 2020
Equity [Abstract]
Schedule of Accumulated Other Comprehensive Income (Loss)	The following table provides information on changes in accumulated other comprehensive loss for the periods presented: Three Months Ended Six Months Ended (in thousands of dollars) Defined Benefit Pension Plan Total Defined Benefit Pension Plan Total April 4, 2020 Beginning Balance $ (55,827 ) $ (55,827 ) $ (56,154 ) $ (56,154 ) Amounts reclassified from other comprehensive loss and included in earnings 429 429 859 859 Total other comprehensive income, before taxes 429 429 859 859 Income tax expense (103 ) (103 ) (206 ) (206 ) Ending Balance April 4, 2020 $ (55,501 ) $ (55,501 ) $ (55,501 ) $ (55,501 ) March 30, 2019 Beginning Balance $ (37,903 ) $ (37,903 ) $ (38,427 ) $ (38,427 ) Amounts reclassified from other comprehensive loss and included in earnings 690 690 1,379 1,379 Total other comprehensive income, before taxes 690 690 1,379 1,379 Income tax expense (166 ) (166 ) (331 ) (331 ) Ending Balance March 30, 2019 $ (37,379 ) $ (37,379 ) $ (37,379 ) $ (37,379 )

Summary of Significant Accoun_2

Summary of Significant Accounting Policies and Recently Issued Accounting Standards Significant Accounting Policies - Narrative (Details) - USD ($) $ in Thousands	3 Months Ended	12 Months Ended
	Jan. 04, 2020	Oct. 03, 2020	Sep. 28, 2019	Sep. 30, 2018
Revenue, Initial Application Period Cumulative Effect Transition [Line Items]
Percentage of active participants (less than)	10.00%
Amortization period of deferred pension losses			7 years
Accounting Standards Update 2014-09
Revenue, Initial Application Period Cumulative Effect Transition [Line Items]
Adoption of new revenue recognition standard (ASC 606) adjustment				$ (714)
Scenario, Forecast | Subsequent Event
Revenue, Initial Application Period Cumulative Effect Transition [Line Items]
Amortization period of deferred pension losses		23 years

Supplemental Financial Inform_3

Supplemental Financial Information - Inventories (Details) - USD ($) $ in Thousands	Apr. 04, 2020	Sep. 28, 2019
Condensed Financial Information [Abstract]
Raw materials	$ 116,386	$ 60,033
Work in process	18,089	16,663
Finished goods	9,467	2,134
Total inventories	$ 143,942	$ 78,830

Supplemental Financial Inform_4

Supplemental Financial Information - Product Warranty Rollforward (Details) - USD ($) $ in Thousands	3 Months Ended		6 Months Ended
	Apr. 04, 2020	Mar. 30, 2019	Apr. 04, 2020	Mar. 30, 2019
Movement in Standard Product Warranty Accrual [Roll Forward]
Balance at beginning of period	$ 21,731	$ 21,858	$ 22,343	$ 22,646
Add current period accruals	2,628	2,248	4,129	3,838
Current period reductions of accrual	(2,961)	(2,586)	(5,074)	(4,964)
Balance at end of period	$ 21,398	$ 21,520	$ 21,398	$ 21,520

Supplemental Financial Inform_5

Supplemental Financial Information - Extended Warranty Income (Details) - USD ($) $ in Thousands	3 Months Ended		6 Months Ended
	Apr. 04, 2020	Mar. 30, 2019	Apr. 04, 2020	Mar. 30, 2019
Movement in Extended Product Warranty Accrual [Roll Forward]
Balance at beginning of period	$ 22,744	$ 22,532	$ 24,045	$ 23,191
Add current period deferred income	2,338	2,440	3,289	3,806
Current period recognition of income	(2,134)	(2,071)	(4,386)	(4,096)
Balance at end of period	$ 22,948	$ 22,901	$ 22,948	$ 22,901

Supplemental Financial Inform_6

Supplemental Financial Information Remaining Performance Obligation (Details) $ in Millions	Apr. 04, 2020USD ($)
Revenue, Remaining Performance Obligation, Expected Timing of Satisfaction, Start Date [Axis]: 2020-04-05
Revenue, Remaining Performance Obligation, Expected Timing of Satisfaction [Line Items]
Revenue, remaining performance obligation	$ 4.5
Revenue, performance obligation, (in years)	6 months
Revenue, Remaining Performance Obligation, Expected Timing of Satisfaction, Start Date [Axis]: 2020-09-29
Revenue, Remaining Performance Obligation, Expected Timing of Satisfaction [Line Items]
Revenue, remaining performance obligation	$ 7.4
Revenue, performance obligation, (in years)	1 year

Supplemental Financial Inform_7

Supplemental Financial Information - Self Insurance (Details) - USD ($) $ in Thousands	Apr. 04, 2020	Sep. 28, 2019
Condensed Financial Information [Abstract]
Current portion	$ 3,120	$ 2,933
Long-term portion	1,935	1,775
Total accrued self-insurance	$ 5,055	$ 4,708

Supplemental Financial Inform_8

Supplemental Financial Information - Narrative (Details) - USD ($) $ in Thousands	3 Months Ended		6 Months Ended
	Apr. 04, 2020	Mar. 30, 2019	Apr. 04, 2020	Mar. 30, 2019
Product Warranty Liability [Line Items]
Shipping and handling revenues	$ 255,412	$ 211,642	$ 408,629	$ 366,568
Minimum
Product Warranty Liability [Line Items]
Extended product warranty, period			2 years
Maximum
Product Warranty Liability [Line Items]
Extended product warranty, period			5 years
Shipping and Handling
Product Warranty Liability [Line Items]
Shipping and handling revenues	4,100	3,200	$ 7,600	6,500
Shipping and handling cost of goods sold	$ 3,500	$ 2,700	$ 6,600	$ 5,700

Supplemental Financial Inform_9

Supplemental Financial Information - Pension Expense (Details) - USD ($) $ in Thousands	3 Months Ended		6 Months Ended
	Apr. 04, 2020	Mar. 30, 2019	Apr. 04, 2020	Mar. 30, 2019
Condensed Financial Information [Abstract]
Interest cost	$ 1,237	$ 1,511	$ 2,474	$ 3,023
Expected return on plan assets	(1,846)	(1,904)	(3,692)	(3,809)
Amortization of prior loss	429	690	859	1,379
Net periodic benefit cost	(180)	297	(359)	593
Amortization of prior loss, recognized in other comprehensive income	429	690	859	1,379
Total recognized in net periodic pension benefit cost and other comprehensive income	$ (609)	$ (393)	$ (1,218)	$ (786)

Supplemental Financial Infor_10

Supplemental Financial Information Supplemental Financial Information - Derivative Instruments (Details) - USD ($) $ in Millions	Nov. 30, 2018	Apr. 04, 2020
Condensed Financial Information [Abstract]
Interest rate collar	4 years
Derivative, notional amount	$ 150
Floor interest rate	1.50%
Ceiling interest rate	3.30%
Fair value of interest rate contract		$ (3.4)

Debt - Narrative (Details)

Debt - Narrative (Details) - USD ($) $ in Thousands	3 Months Ended		6 Months Ended
	Apr. 04, 2020	Mar. 30, 2019	Apr. 04, 2020	Mar. 30, 2019	Sep. 28, 2019
Debt Instrument [Line Items]
Interest expense	$ 5,700	$ 4,000	$ 7,600	$ 6,900
Senior Term Loan | Senior Credit Facility
Debt Instrument [Line Items]
Long-term line of credit	$ 181,300		$ 181,300		$ 186,300
Stated interest rate (as a percent)	3.20%		3.20%		4.40%
Weighted average effective interest rate (as a percent)	4.50%		4.50%		5.00%
Revolving Credit Facility | Line of Credit | Senior Revolving Credit Facility
Debt Instrument [Line Items]
Long-term line of credit	$ 30,000		$ 30,000
Letters of Credit | Line of Credit | Senior Revolving Credit Facility
Debt Instrument [Line Items]
Letters of credit, amount outstanding	6,900		6,900
Remaining borrowing capacity	$ 63,100		$ 63,100

Debt - Schedule of Long-term De

Debt - Schedule of Long-term Debt (Details) - USD ($) $ in Thousands	Apr. 04, 2020	Sep. 28, 2019
Debt Instrument [Line Items]
Current portion of long-term debt	$ 9,900	$ 9,900
Long-term debt	168,715	173,226
Senior Term Loan | 2023 Term Loan
Debt Instrument [Line Items]
Total debt	178,615	183,126
Deferred financing costs	$ 2,685	$ 3,124

Debt - Maturity Schedule (Detai

Debt - Maturity Schedule (Details) $ in Thousands	Apr. 04, 2020USD ($)
Long-term Debt, Fiscal Year Maturity
2020	$ 4,950
2021	9,900
2022	14,850
2023	181,600
Total debt	$ 211,300

Income Taxes (Details)

Income Taxes (Details)	3 Months Ended		6 Months Ended
	Apr. 04, 2020	Mar. 30, 2019	Apr. 04, 2020	Mar. 30, 2019
Income Tax Disclosure [Abstract]
Effective tax rate (as a percent)	70.00%	14.40%	55.40%	15.80%
Statutory Federal income tax rate (as a percent)	21.00%	21.00%	21.00%	21.00%

Guarantees, Commitments and C_2

Guarantees, Commitments and Contingencies Gaurantees, Commitments and Contingencies - Narrative (Details) $ in Millions	6 Months Ended
	Apr. 04, 2020USD ($)
Lessee, Lease, Description [Line Items]
Maximum exposure of guarantor	$ 3
Fair value of guarantees	$ 0.3
Remaining maturity on term loan on guarantee (up to)	2 years 9 months
Minimum
Lessee, Lease, Description [Line Items]
Operating lease term	4 years 8 months
Maximum
Lessee, Lease, Description [Line Items]
Operating lease term	7 years 8 months

Segment Information (Details)

Segment Information (Details) $ in Thousands	3 Months Ended		6 Months Ended
	Apr. 04, 2020USD ($)	Mar. 30, 2019USD ($)	Apr. 04, 2020USD ($)segment	Mar. 30, 2019USD ($)
Segment Reporting Information [Line Items]
Number of Operating Segments | segment			2
Net sales	$ 255,412	$ 211,642	$ 408,629	$ 366,568
Gross profit	24,169	25,954	45,469	45,064
United States
Segment Reporting Information [Line Items]
Net sales	232,477	191,684	368,743	343,169
Canada
Segment Reporting Information [Line Items]
Net sales	22,746	18,784	35,902	21,860
Rest of world
Segment Reporting Information [Line Items]
Net sales	189	1,174	3,984	1,539
Operating Segments
Segment Reporting Information [Line Items]
Gross profit	24,169	25,954	45,469	45,064
Operating Segments | Bus
Segment Reporting Information [Line Items]
Net sales	238,697	195,065	373,469	334,275
Gross profit	17,938	20,142	32,805	33,657
Operating Segments | Parts
Segment Reporting Information [Line Items]
Net sales	16,715	16,577	35,160	32,293
Gross profit	6,231	5,812	12,664	11,407
Intersegment Eliminations | Parts
Segment Reporting Information [Line Items]
Net sales	$ 1,200	$ 900	$ 2,400	$ 1,500

Segment Information - Reconcili

Segment Information - Reconciliation of Segment Gross Profit (Details) - USD ($) $ in Thousands	3 Months Ended		6 Months Ended
	Apr. 04, 2020	Mar. 30, 2019	Apr. 04, 2020	Mar. 30, 2019
Segment Reporting, Reconciling Item for Operating Profit (Loss) from Segment to Consolidated [Line Items]
Segment gross profit	$ 24,169	$ 25,954	$ 45,469	$ 45,064
Selling, general and administrative expenses	(19,858)	(22,928)	(40,353)	(40,201)
Interest expense	(5,658)	(3,998)	(7,555)	(6,872)
Interest income	0	0	0	9
Other income (expense), net	180	(275)	374	(624)
Loss before income taxes	(1,167)	(1,247)	(2,065)	(2,624)
Operating Segments
Segment Reporting, Reconciling Item for Operating Profit (Loss) from Segment to Consolidated [Line Items]
Segment gross profit	24,169	25,954	45,469	45,064
Segment Reconciling Items
Segment Reporting, Reconciling Item for Operating Profit (Loss) from Segment to Consolidated [Line Items]
Selling, general and administrative expenses	(19,858)	(22,928)	(40,353)	(40,201)
Interest expense	(5,658)	(3,998)	(7,555)	(6,872)
Interest income	0	0	0	9
Other income (expense), net	$ 180	$ (275)	$ 374	$ (624)

Revenue (Details)

Revenue (Details) - USD ($) $ in Thousands	3 Months Ended		6 Months Ended
	Apr. 04, 2020	Mar. 30, 2019	Apr. 04, 2020	Mar. 30, 2019	Sep. 30, 2018
Disaggregation of Revenue [Line Items]
Net sales	$ 255,412	$ 211,642	$ 408,629	$ 366,568
Diesel buses
Disaggregation of Revenue [Line Items]
Net sales	113,649	110,487	190,399	200,307
Alternative fuel buses
Disaggregation of Revenue [Line Items]
Net sales	113,057	75,320	164,791	118,401
Other
Disaggregation of Revenue [Line Items]
Net sales	12,505	9,773	19,348	16,575
Parts
Disaggregation of Revenue [Line Items]
Net sales	$ 16,201	$ 16,062	$ 34,091	$ 31,285
Accounting Standards Update 2014-09
Disaggregation of Revenue [Line Items]
Adoption of new revenue recognition standard (ASC 606) adjustment					$ (714)

Earnings Per Share - Summary of

Earnings Per Share - Summary of Basic and Diluted Earnings Per Share (Details) - USD ($) $ / shares in Units, $ in Thousands	3 Months Ended		6 Months Ended
	Apr. 04, 2020	Mar. 30, 2019	Apr. 04, 2020	Mar. 30, 2019
Earnings Per Share [Abstract]
Net loss	$ (639)	$ (673)	$ (1,042)	$ (1,893)
Weighted-average common shares outstanding	26,866,822	26,595,280	26,667,860	26,449,072
Effect of dilutive securities	0	0	0	0
Weighted-average shares and dilutive potential common shares	26,866,822	26,595,280	26,667,860	26,449,072
Basic loss per share	$ (0.02)	$ (0.03)	$ (0.04)	$ (0.07)
Diluted loss per share	$ (0.02)	$ (0.03)	$ (0.04)	$ (0.07)

Earnings Per Share - Narrative

Earnings Per Share - Narrative (Details) - shares shares in Millions	3 Months Ended
	Apr. 04, 2020	Mar. 30, 2019
Earnings Per Share [Abstract]
Anti-dilutive securities excluded from computation of earnings per share (in shares)	0.5	1.4

Accumulated Other Comprehensi_3

Accumulated Other Comprehensive Loss (Details) - USD ($) $ in Thousands	3 Months Ended		6 Months Ended
	Apr. 04, 2020	Mar. 30, 2019	Apr. 04, 2020	Mar. 30, 2019
AOCI Attributable to Parent, Net of Tax [Roll Forward]
Beginning Balance			$ (67,811)
Ending Balance	$ (65,063)		(65,063)
Defined Benefit Pension Plan
AOCI Attributable to Parent, Net of Tax [Roll Forward]
Beginning Balance	(55,827)	$ (37,903)	(56,154)	$ (38,427)
Amounts reclassified from other comprehensive loss and included in earnings	429	690	859	1,379
Total amount recognized in other comprehensive loss	429	690	859	1,379
Income tax expense	(103)	(166)	(206)	(331)
Ending Balance	(55,501)	(37,379)	(55,501)	(37,379)
AOCI Attributable to Parent
AOCI Attributable to Parent, Net of Tax [Roll Forward]
Beginning Balance	(55,827)	(37,903)	(56,154)	(38,427)
Amounts reclassified from other comprehensive loss and included in earnings	429	690	859	1,379
Total amount recognized in other comprehensive loss	429	690	859	1,379
Income tax expense	(103)	(166)	(206)	(331)
Ending Balance	$ (55,501)	$ (37,379)	$ (55,501)	$ (37,379)

Subsequent Event (Details)

Subsequent Event (Details) - Line of Credit - Revolving Credit Facility - USD ($)	May 07, 2020	Sep. 13, 2018
First Amendment to Credit Agreement
Subsequent Event [Line Items]
Basis spread on variable rate (as a percent)		0.00%
Second Amendment to Credit Agreement | Subsequent Event
Subsequent Event [Line Items]
Additional revolving commitments by lender	$ 41,900,000
Maximum borrowing capacity	$ 141,900,000
Basis spread on variable rate (as a percent)	0.75%
Capitalized debt fees	$ 900,000

Uncategorized Items - blbd-2020

Label	Element	Value
Accounting Standards Update 2014-09 [Member] | Retained Earnings [Member]
Cumulative Effect of New Accounting Principle in Period of Adoption	us-gaap_CumulativeEffectOfNewAccountingPrincipleInPeriodOfAdoption	$ (714,000)