Rather than write a lengthy longhand report, I decided to simply post a few bullet points about what I found most interesting:
- The tour started at 2PM, which is a time where there is no build activity underway. The factory workers are on an eight-hour shift from 04:30AM to 12:30PM. We were told that most workers are Amish people from the area, so after they leave the factory, they go and work on their “day job” which is tending to their farm.
- They fully build an RV over a period of two days. At any point in time, there are 40 partially built RVs in the factory, so 20 go out the door each day. Each station represents one step in the process. For example, station one attaches the Dexter-manufactured axles to the Lippert-manufactured frame
- Other frame-related steps include installing the hydraulic rams for the slideouts, the self-leveling jacks, the fresh, grey and blackwater tanks, color-coded electrical wiring that runs under the floor, and the Coroplast that is attached to the underside of the frame.
- Then the actual floor is added as its own structure. It has a one-piece 8 ft wide by 24 ft long piece of plywood (no joints) mounted on an aluminium frame. Inside that frame are the heating ducts and the PEX water lines. Under that frame is a heat reflective foil. That they say is their secret why pipes don’t freeze on Montana RVs. Once the floor structure is attached to the frame, the vinyl flooring is added, and now they are ready to start building up
- Unlike a house, they pointed out to us that they build RVs from the inside out. So the various inside cabinets and walls go up before the outside walls are installed. This includes the one-piece shower, which the tour guide is the only part in the whole RV that cannot be taken out though the door.
- Eventually the outside walls and roof are installed, including A/C units and ceiling fans. There are still huge holes in the sides, where the slideouts will go.
- Then the slideouts get put in, with the related appliances or furniture installed
- Then its time for finishing touches and quality control before the unit goes out the door.
This was a fun and memorable experience.
Frame before floor gets added on
One-piece floorboard
partially constructed inside
slideout being assembled