The Rally highlight for most attendees is probably the factory tour on the Saturday morning. Being the weekend, no production is taking place, which permits us a detailed look at the production line, without getting in the way. If you want to view the production process, tours are available upon request.
The factory is about 30 miles from the campground, so it was an early start to the morning, getting dogs fed and walked, and the mandatory cups of tea for the journey. Breakfast was provided at the factory, but as we correctly figured no tea was available, so we brought our own. Left the campground around 08:30 and had a leisurely drive South through the Indiana farming community to Hwy 13 in Syracuse, Indiana. Ace Navigator did an excellent job locating the factory, but Jackie Stewart at the wheel went screaming past the entrance and had to turn around.
Daily activity started with breakfast and a quick pep talk from Jim (GM), then we were split into 4 groups for a tour led by a Redwood representative. The factory currently produces Redwoods and two Crossroads products – top of the line Rushmore and their Elevation Toy Hauler. This is currently changing as the final Rushmores are currently on the line and Redwood is introducing 2 new products – entry level Cypress and mid level Sequoia. Current production levels are 7 per day.
Bay # 1 – Axle & Wheel Installation
The frame enters the factory inverted and in Bay # 1 they install the running gear. This is the Lippert system with a new yellow Equaflex and disk brakes. At the Q & A the previous day, as owners, we requested options for an upgraded suspension, either the Lippert air bag or MOR/Ryde IS.
Bay # 2 – Tanks, Wiring & Hydraulics
Fresh water tank (white) installed, which is immediately behind the pin. At 109 gallons, if full it adds about 800 lbs to the pin weight. Valves are sitting on top ready for installation. All tanks, once installed, are filled and leak tested.
The electrical wires and hydraulic lines are also run at this bay.
Bay # 3 – Flooring
The floors are manufactured in advance of the frame arriving in Bay # 3, using actual plywood, not OSB or sawdust board. Even the flooring material is already installed.
Floor installed in Bay # 3.
Bay # 4 – Upper Deck Framing
Aluminium framing being installed for the upper deck floor and basement in a front bedroom unit.
Bay # 6 – Plumbing
Bathroom and plumbing being installed in a 38 FL (front living) model.
Bay # 7 – Sidewalls and Roof
Similar to the flooring the sidewalls and roof are pre-manufactured and then installed at this and the next bay.
Bay # 9 – Fitting Out
Possibly a Rushmore model just after installation of the sidewalls and roof, with electrical cables being run down the rear.
Bay # 10 – Fitting Out & Exterior Doors
This is Redwood’s new mid-point coach the Sequoia getting exterior doors installed and fitted out on the inside.
Bay # 11 – Front Cap Install
Another Sequoia with the front cap installed.
Bay # 12 – Slide-Outs
Slide-outs are almost completely pre-manufactured and sit awaiting their frame to arrive for installation.
Bay # 13 – Windows
Windows being installed
Bay # 14 – Inside Fitting
A 39 MB with the kitchen and living room entertainment centre being finished.
A 39 MB bedroom being finished
Bay # 15 – New Redwood For Hershey Show
This is the new 2015.5 model that will be introduced at the Hershey Show in September. New counters with lighting around the edge and base, new bulkhead covering, tablet controls for lights, etc
Fitting Out Bays
Once they return from paint they go to the fitting out bay for PDI inspection and installation of furniture and any outstanding appliance or fixtures.
New residential fridge with water and ice through the door – nice.