Build-A-Motorhome

So, would you like a motorhome?
Why not build it yourself?
It looks easy....
if you have the space,
the materials,
and the tools....
oh, and 850 workers!
(Over 1500 are needed for outside services as well)

Well, maybe you won't want to build one after all!
Mr. Dreamy & I enjoyed a tour of the
Tiffin plant in Red Bay, AL.
I thought you might enjoy a look inside, too.

A basic chassis is driven to the assembly plant.

Tiffin uses some chassis manufactured elsewhere,

and some they assemble at the factory,
depending on the style of the motorhome.

(Did you know that the plural of chassis is... chassis?!)

 Additional steel is welded to the chassis to support storage bays,
water tanks and the floor.

Up to 3 miles of wire is used in each motorhome. 

Wiring harnesses are created for each model.

Wires are labeled by computers and cut individually.

They are laid out along this board 

and sections are taped together.

One of the wire harnesses is installed along the chassis.

More wire is enclosed in walls and the ceiling at 

other points in the assembly area.

CNC machines cut huge sheets of foam layered with other materials

for the floor and the roof of the motorhome.
Cutouts are made for roof vents, lights and wiring.
This machine zips along and little widgets of foam fly all over.
On a bad static day I wonder if the workers go home looking
like little snowmen?

The tile floor for some models is glued down on sub flooring and

grouted at another location and brought to the factory in one piece.

This 'suction' rig will pick the floor up and lay it on top 

of the precut layered foam sandwich that was mounted on the chassis. 

Cabinets, doors and appliances are assembled,

and are ready to be placed on the flooring.

All cabinetry is built at the factory in a huge cabinet shop.

Walls are put together offsite.

Here is the "Flat Stanley" model of a motorhome.

Once everything is inside the motorhome, the walls are put in place.

The roof is almost ready to be placed on the motorhome.

Notice that all roof-top equipment is in place.

 Slide outs, complete with furniture and window treatments,

are ready to be slid into the openings of the walls.

Here goes the slide out.
Geesh, that worker is strong -
look at him lift that slideout as if it weighs nothing,
and one handed, at that!
;-)

The motorhome moves on, 

getting the front cap, windows,

and doors for the storage bays.

The front cap is fully assembled, with wiring and windshield 

 before it is put into place.

Finally, the motorhome goes to another site for painting.

It will return to the factory for inspection and cleaning,

and for minor repairs.

Looks easy, right?

What factories have you enjoyed visiting?