The invention discloses a novel bus lateral cabin door structure and a manufacturing process thereof. The lateral cabin door structure comprises a lateral cabin door body, a hinge fixing base, a rotation shaft sleeve and a door frame sealing profile, wherein the lateral cabin door body comprises an aluminum door plate, an aluminum framework and a lateral cabin door upper fixing profile, the aluminum door plate is connected with the aluminum framework through adhesive glue, the upper portion of the lateral cabin door upper fixing profile is of an arc structure and is provided with a hinge fixing hole and a door plate embedding groove, the hinge fixing base and the rotation shaft sleeve are connected through the hinge fixing hole, the lateral cabin door upper fixing profile is connected with the door plate through the door plate embedding groove, and the lateral cabin door body is connected with the door frame sealing profile in a welding mode. The novel bus lateral cabin door structure adopts a novel single-shaft hinge which is provided with only one movement pair, the frictional force is reduced to the maximum extent, energy loss is lowered, and therefore a cabin door can be opened and closed flexibly and conveniently, and the strength in the hinge position of the lateral cabin door is guaranteed.