Our New Factory

We manufacture campers in batches on a weekly cycle with a two-week completion time. That means that when your camper is scheduled to begin, a process starts that takes two weeks to complete. Here's a breakdown of what that process looks like.

Build Details

Sometime before the scheduled build week, we gather the build details from the customer. Things like color options, window preferences, delivery method, etc. These get entered into a fancy spreadsheet that our employees on the shop floor use to coordinate the build.

Fabrication

 The weekly batch of parts getting ready for powder coating.

The weekly batch of parts getting ready for powder coating.

With the customer details locked in, Metal Town kicks off the build process by making space frames and aluminum panel sets. Right now we're building five campers per week, so for each new build week Metal Town will cut and weld up five space frames, cut, bend, and rivet five side panel sets, and cut five sets worth of tent frame extrusion. This process takes one week, at the end of which the new parts are dropped off at powder coating and the parts from the previous week's build are picked up and moved into Assembly Town.

 Side panels getting cut. From here they get deburred, bent, and stiffeners get riveted on before heading off to powder coat.

Side panels getting cut. From here they get deburred, bent, and stiffeners get riveted on before heading off to powder coat.

 Tube sets for the week's space frames getting cut and labeled.

Tube sets for the week's space frames getting cut and labeled.

 A sheet of Tacoma mounting brackets getting cut. Seems like we can never make enough of these. Tacomas must be popular or something.

A sheet of Tacoma mounting brackets getting cut. Seems like we can never make enough of these. Tacomas must be popular or something.

 Metal Town also spends the week making larger batches of parts as well. Here we have a bunch of mounting tabs and brackets getting prepped for welding.

Metal Town also spends the week making larger batches of parts as well. Here we have a bunch of mounting tabs and brackets getting prepped for welding.

 Extrusion cutting beast. 

Extrusion cutting beast. 

Assembly

Once parts are back from powder a whole lot of steps have to happen. We start by assembling the tent frames. Then we rivet hinges onto the side panels, install the struts, latches, and gaskets, and bolt the panels and tent frames onto the space frame. It's starting to look like a camper now. Next the floors get installed, the tent fabric gets snapped in, the graphics are applied, and the mattress cushions put in. The assembly process takes about a week as well.

 Hinges getting riveted onto a freshly powder coated side panel.

Hinges getting riveted onto a freshly powder coated side panel.

 Space frame and tent frame get mated together then side panels installed. Note the custom red finish on this one.

Space frame and tent frame get mated together then side panels installed. Note the custom red finish on this one.

Meanwhile, In Fabric Town

While all this is going on, Fabric Town is busy cranking out tents and mattresses. Parts get cut on the cnc fabric cutter, then they get welded, sewn, or glued depending on the part. We built a giant heat press to accommodate the size of the tent panels.

 Custom heat press can glue up an 8' long seam.

Custom heat press can glue up an 8' long seam.

 Racks of precut parts waiting to be sewn into mattress cushions.

Racks of precut parts waiting to be sewn into mattress cushions.

 The week's tents stacking up.

The week's tents stacking up.

So that's a basic overview of the build process and timeline. Right now we're producing five per week and it takes two weeks for a camper to move through the process start to finish.