It’s an unforgettable feeling… walking into your new motorhome.
The sights of the detail and craftsmanship.
Touching the surfaces… and the smell of real wood and leather.
It took a team of artisans hours and hours of hard work to get here….
And it all starts with this.
TRACK: Our Chassis’ come from a number of different manufacturers…
Ford, Mercedes-Benz, Chevy and Freightliner.
The chassis is chosen based on the size and market for each product in the Thor line-up.
Our engineers design the platform… and the chassis is sent to an outside modifier who
specializes in steelwork.
The foundation is what everything rides on, it needs to be flat and square since the sidewalls,
and roof and floors are made to fit.
Some chassis may be modified in a way that increases the overall wheelbase so the motorhome
has optimal handling and storage capacity.
Our engineers work diligently to design every motorhome structure with best weight distribution
possible, from the front axle, to the rear axle, driver’s side to passenger side.
That’s why we use horizontal steel trusses that support the weight.
This also allows us to create storage solutions for every floorplan… be it pass through
storage or extremely large bay storage.
Regardless of which motorhome you choose - the storage is set-up to handle all of your belongings
and durable enough to last the lifetime of the motorhome.
Once the chassis is back from the modifier, the floor gets installed.
The OSB decking is laid down and securely fastened to the frame.
Notice the steel tubing…. it runs the entire perimeter and throughout the structure of
the floor.
Not only does this lower the center of gravity... the results are a better ride and reduced
overall road noise from the exterior of the motorhome.
The seatbelts are mounted.
Did you know Thor Motor Coach pull tests the seat belts to make sure our motorhomes are
safe for you and your family?
All motorhomes have pet and kid friendly flooring options…
Meaning it’s durable and easy to clean.
This is an example of our Residential vinyl flooring.
Take a look at how it’s laid down… from front to back... before the cabinets are installed.
This means no gaping, no cutting and pasting and no peeled up edges.
We also use hand laid porcelain tile flooring in some of the larger diesel models.
We mount our tile on a Hardie backer...
Resistant to moisture, mold, buckling and cracking… so your floor will last a lifetime.
It’s at this point another member of the crew installs the generator.
Here comes the heavy lifting as the team puts the cabinets in place.
All the Cabinet work is installed before the sidewalls are attached and securely fastened
into the floor.
At Thor Motor Coach, all the cabinet construction is done in house by people who know the coaches
and the floorplans they are working on.
The art of building cabinets in a motorhome is providing the same look and feel of what
you have in your home … combined with the longevity and strength needed for an automotive
application.
Here’s something else that sets Thor Motor Coach apart... our beautiful, – handcrafted
cabinet doors.
Regardless of which model you choose, all cabinet doors are solid wood with a complementing
stain to match the interior décor.
Moving down the line, take a look at how we run our plumbing, electrical and duct work.
See how it is on top of the floor?
We do this to make them accessible should you need service once the sidewalls are mounted
Taking it one step further, notice the two different colored water lines… red is for
hot water, blue is for cold.
Some manufactures use the same white colored line for hot and cold - making it nearly impossible
to tell what is being worked on.
We need our wire harnesses to have the same attention to detail.
As some manufactures use a one size fits all mindset, ours are color coded and designed
for a specific floorplan - which is why we build our own harnesses in a state of the
art harness shop.
This cuts down on weight and piles of extra wire taking up precious cargo space.
After the harness is built - it is quality tested.
This may be a small detail… but it’s an important one.
Our wire harnesses are connected together by locking pins.
Using this method means it will be able to withstand the vibrations from the bumpiest
highway or rockiest trail.
The Electrical system is very similar to the one in your house, along with that of your
car.
You’ll find 110 volt breakers and 12V fuses.
It’s here the electrical system - along with outlets, inverters and converters are
installed.
When we install the furnace…the ducts are run to the areas where you want heat.
And just like the plumbing and electrical… the duct work is run for easy access.
Let’s talk about sidewalls and how we build them at Thor Motor Coach
The sidewalls...
Along with the floor and roof - go through an intensive lamination process.
After the aluminum frame is constructed… it ls laid down and insulated with a low density
polystyrene foam.
It is then hoisted onto the lamination table where it is placed on flat sheets of fiberglass.
Beads of glue are then run an inch apart down the entire surface.
A fine mist of water is sprayed on the glue to activate it.
The structure is then rolled into the lamination machine…
Here, all the air is removed and pressure is applied.
This causes all the surfaces to be vacuum bonded together forming a strong, resilient
structure.
After the designated time… the structure is removed from the lamination bed and a team
armed with routers moves in to cut out the spaces for windows, doors and vents.
It’s time to take that laminated sidewall and attach it to the motorhome.
The entire wall is now anchored in place.
The SLIDE wall is removed after the entire SIDEwall is set to ensure a perfect fit every
time.
That’s because we build our slide rooms out of the exact piece of fiberglass wall
it was cut from.
We do this every time, for every coach.
What this means for you - is it is always going to match and it is always going to fit.
The other guys build a stock pile of walls and insert any random wall into the next coach
in line.
Before we reattached the slide wall, bigger pieces of furniture and appliances are set
in place.
After the Slide out room is crafted… it’s inserted back into the wall... on a leveled
coach… before mounting... that way the wall stays square
It’s time to raise the roof.
Notice the shape?
See how it’s domed…this allows optimal water and debris run-off as you travel down
your favorite road… or when forging a new path.
Before we put on the front cap… the one piece windshield is installed to keep the
cap square.
The glass is installed just like in your car with a urethane adhesive.
Now that it’s shaping up to look like a motorhome… it’s time to install the roof
mounted Air-conditioned, vents, and TV antennas Many motorhomes will have Thor Motor Coach’s
HD-MAX exterior fiberglass with vinyl graphics...
While others will be shipped off to the paint shop for a glossy coat of Full Body Paint.
At this point, it’s time to install those comfortable sofas and theater seats along
with other furniture and appliances.
After the Awnings and slide-out toppers are installed, the motorhome is now ready to head
out for a road test.
An exhaustive drive down the country roads, highways and through town make sure the motorhome
is road worthy.
Once back from the road, we rain test every unit to make sure everything is sealed and
ready for the great outdoors.
Finally a stop in the Audit building.
Here, each unit is given a systems check.
The coach is weighed and any imperfections are tagged for final repair before the motorhome
is released to ship to a dealer near you.
From here... our motor homes head to you so you can build your own stories… your own
memories… and you can do it in a Motor Home that’s made to fit.