Print Page | Close Window

R Pod Plant Tour

Printed From: r-pod Nation
Category: Forest River r-pod
Forum Name: Miscellaneous / Off-topic
Forum Description: Got something to share or a question to ask. Do it here...
URL: http://www.rpodNation.com/forum_posts.asp?TID=1313
Printed Date: 28 Mar 2024 at 1:34pm
Software Version: Web Wiz Forums 11.0 - http://www.webwizforums.com


Topic: R Pod Plant Tour
Posted By: Sandpiper
Subject: R Pod Plant Tour
Date Posted: 16 Apr 2010 at 5:20pm
Mrs 'Piper and I were treated to a very complete tour of the R Pod factory in Goshen, In Tuesday April 13.  Our hostess and tour guide was the gracious Kristin Griffin, sales coordinator, for Forest river.  Before we showed up at the plant we had asked if it were permissible to take photographs in the plant and were told we couldn't so I left the camera in the car.  During the four hour tour, Kristin suggested I fetch the camera and take what every pictures I wanted within certain guide lines.  I was ecstatic because now we can share some of what we saw with the members of the forum.  
I hope the following pictures and descriptions will make you feel better about how your R Pods are constructed.  I know I feel a lot better about our 177 now that I have seen what I saw Tuesday.
What the pictures don't show is the dedication, determination, commitment to quality, and pride of the R Pod workforce.  I have spent 40 plus years in the industrial workforce and was very, very impressed with the people that build our R Pods.
So let the tour begin. 

One of the things that is asked repeatedly is "What is in the walls of the R Pod. 
This is the basic frame made on a jig out of welded square aluminum tubing.  I could guess at what the number of the aluminum  composition is but it doesn't matter.




The next picture is the opposite side of the same model of R Pod.






The frame is then filled with Styrofoam insulation as shown in the next photograph.
Notice how how the foam tightly fills the cavities.



Once the cavities are filled with insulation, the outside and inside coverings are laminated to the frames.  The coverings are made of luan laminated to either white fiberglass sheet for the outside or patterned material for the inside.  Once the "skins" are attached to the frames all openings are routed or drilled out.




These sides are now ready for the decals to be attached and then assembled onto the R Pod on the production line.  The  picture below is of the station where two ladies attach the decals.  Templates are used to lightly mark where the decals are to be attached and one lady does one side while a second lady does the other side.  Notice the yellow A-Frame with R Pod sides on both sides.  This operation is really something to behold.  Both ladies apply decals quicker than I can even think.   Their work is exquisite. 



The final assembly production begins with workers attaching the pre-assembled floor to the assembled under carriage as shown here. 




Once the floor is attached, the undercarriage is turned over and the tanks, tank plumbing, copper tubing and various wires are attached to the bottom of the R Pod.  The assembled axle unit is attached , the wheels and tires are attached and the unit turned back right side up.  The tires are placed into special dollies so the entire unit can be moved from assembly station to assembly station.




To the left in the above picture you can see some of the inside structure joined with the floor unit.  At each station, the materials, sub assemblies etc are staged and ready to joined to the R Pod at that station.
Here are some kitchen sub assemblies waiting to be installed at this station.



The partially assembled R Pod moves steadily down the line with more and more sub assemblies being added and more work being done.  Here is a picture of an R Pod with most of the internal structure installed and the two sides installed and attached to the internal structures.  To the left you can see an R Pod at the previous station with no sides installed yet.



Here is a picture of the final assembly line from station one to a point approximately 3/4 way through the line.



In the center of the above picture you can see a sub assembly of the rear door for a T series R Pod.  The Green item.  This is the door opened up and being pre-assembled to it's frame.

The picture below is the remainder of the production line showing the area where all discrepancies are corrected before the unit is moved to THE FINAL INSPECTION area where the final tags are attached and then the final-final inspection is performed by THE final inspector.  He checks the entire R Pod for any thing that might have been over looked or not corrected.  No R Pod leaves the production area until he gives it his stamp of approval.



The R Pod factory is now producing 24 R Pods a day five days a week.  The plant also makes the Surveyor line of Travel Trailers so the production time is split between R Pods and Surveyors.  Each line is produced for three weeks and then the plant is switched over to the other line for three weeks. 
And interesting thing about this plant is that the R Pods are actually inspected at each assembly station by crew chiefs and roving production supervisors  and each worker is a sort of inspector.  If a discrepancy is found it is marked with narrow strips of colored tape.  If the descrepency is serious the workers at that station are notified immediately and corrective action is taken.  If it is less serious the discrepancy is left until the R Pod reaches the last several stations where specially skilled employees work off the discrepancies and remove the associated tape.  If for what ever reason a very serious problem should occur and it will take a lot of time to fix, rather than stop the production line , the R Pod with the problem is removed from the production line and will sit "off line" until a special crew can fix what ever the problem is and then and only then will it be put back into the production line.

Every R Pod is pressurized with air on the inside and a soapy solutions is sprayed on EVERY place that has a penetration from inside to outside, windows, doors, hose hookups, antennas, air conditioners, vents etc and leaks show up as bubbles in the soap solution.  If leak is found it is sealed before the R Pod is allowed to move to the final inspection area. 

Since one of my hobbies is furniture making I was interested how the cabinets were made.  I learned that only defect free wood ( the name of which has escaped me) is used to make the frames and the frame components are joined together with pocket screws not with staples as I had thought .  Some of the frame work for walls, bed and seat supports etc are stapled but the "furniture " is joined by much better pocket screws.

All sub assemblies whether floors, exterior wall frames, internal wall frames, internal furniture and frames are all made in jigs so there is no variation between one and the next. 

To say the least I was quite impressed with the plants attention to quality and my comfort level with the R Pod and how it is built was improved considerably. 
If anyone has any questions please PM me or post and I will try to answer your questions.    I am going to make another post about the repeating  questions that have come up on the forum.








-------------
Sandpiper
Mrs.'Piper
Ford 150-[Mini Lite 2104S]



Replies:
Posted By: david950
Date Posted: 16 Apr 2010 at 5:32pm
Wow, what a treat!  I love going to factories of all kinds.  Seeing anything made is always cool and interesting.

I think I'm surprised at how many there are!  Of course, at 24/day, 5 days/week, approx. half of the year, we're talking about approx. 3k/year, which isn't a ton, I suppose.  Still, it looks like some bizzaro scene from the "Clone Wars" or something.

I have a couple of questions:

I see all of the rPods sitting with wheels under their jacks - don't they come without these?  I understand they may be there for ease of movement within the plant, but it seems strange they take them off before they ship 'em out.

Did you happen to ask about the over-80" triple light in the rear?

Thanks for the great pics!


Posted By: Sandpiper
Date Posted: 16 Apr 2010 at 5:39pm
david950
I noticed the wheel on the jacks also but with all there was to try to adsorb I failed to ask why they aren't included with the Pod.  The wheels used in the assembly process are different than what you would get if you bought the one for the jack that is furnished with the Pod.  There is a post on the forum for the source of the  jack wheels and I think it is about $11 or $12. Do a search and you should find it.
 Yes I did ask about the "over 80 light bar" but didn't get an answer.  I was told it is being researched and an answer will be forthcoming.


-------------
Sandpiper
Mrs.'Piper
Ford 150-[Mini Lite 2104S]


Posted By: pepperpod
Date Posted: 16 Apr 2010 at 5:48pm
Sandpiper
Thank you so much for the pictures and great info.  If you put your "seal of approval" on the construction, then I feel much better about my Pod.  I am sure that others feel the same.


-------------
Pepper,Coach,and Henry (a very brave little Maltese)
R Pod 172

The rewards of the journey far outweigh the risk of leaving the harbor...unknown


Posted By: david950
Date Posted: 16 Apr 2010 at 5:53pm
Sandpiper,

Thanks for the response.  I've seen that post and do plan to buy a wheel.  I have no issues with the personalization and maintenance required of an RV owner - I've been a boat owner long enough to understand that - it was just a D'oh! moment to see all those rPods sitting on those jack wheels.  I found myself thinking of the last box on the ship out checklist - "remove jack wheel" - LOL!


Posted By: pepperpod
Date Posted: 16 Apr 2010 at 6:05pm

And another thing.........LOL  When I looked at the MPG today at the dealership, I looked closely at the lights on the outside.  There are 3 large red lights near the top at the rear.  The fenders have a smaller red light on the front and back of each fender. Now that I think of it, I think the one on the front of the fender is amber.  Not sure.



-------------
Pepper,Coach,and Henry (a very brave little Maltese)
R Pod 172

The rewards of the journey far outweigh the risk of leaving the harbor...unknown


Posted By: tedbear
Date Posted: 16 Apr 2010 at 6:21pm
The jack does not retract high enough as it is, as many people have reported it scraping the ground (happened to me once, too).  I added a wheel to mine anyway just to test it, and it touched the ground when the camper was hooked to my car.
 
Perhaps if one could cut some of the lower jack post off, it would allow room for a wheel?


Posted By: Ratdog
Date Posted: 16 Apr 2010 at 6:39pm
Originally posted by pepperpod pepperpod wrote:

And another thing.........LOL  When I looked at the MPG today at the dealership, I looked closely at the lights on the outside.  There are 3 large red lights near the top at the rear.  The fenders have a smaller red light on the front and back of each fender. Now that I think of it, I think the one on the front of the fender is amber.  Not sure.

You're correct. The "80 inch rule" requires amber lamps on the front fenders and red lamps on the rear fenders. That's in addition to the 3-light bar on the coach.
 
You don't happen to know the width of the MPG coach (not counting the wheels/fenders) do you?
 
Take care,
-- Steve


-------------

Steve, Anne, and Paige the Rat Terrier
2013 Lexus RX 450h Hybrid AWD
2011 RP-177 (aka: The Circus Wagon)


Posted By: R&T's Pod
Date Posted: 16 Apr 2010 at 7:16pm
Great Pictures and Great Report!  Thanks!
Rob


-------------
2010 R-Pod 175 2007 F-150 Super Cab http://www.rtspod.blogspot.com" rel="nofollow - R&T's Podding Blog



Posted By: GrandPod
Date Posted: 16 Apr 2010 at 7:30pm
Wink Wow!! Super report Sandpiper. Just like being there myself. Thanks for sharing.
 Tom


-------------
Tom And Linda
Rpod 177                      Southwest florida


  


Posted By: Peggy L.
Date Posted: 16 Apr 2010 at 7:37pm
Great report. Thank you so much for posting all the pictures. They were fascinating - and we now have an idea where to find studs if we should decide to actually drill into the walls.
 
Over the past few months I've come to realize that you are one of those perfectionists among us. If you were impressed by the quality of the production process, that's really saying something.


-------------
Traveling with Herb and the Boon-doggie

2010 r-pod 171 pulled by '11 Silverado


Posted By: pepperpod
Date Posted: 16 Apr 2010 at 11:20pm
Steve
I picked up an MPG brochure but it is in the truck.  I will find it tomorrow and let you know what the width is if it is cited.  I do know that it is longer and higher than the Pod.


-------------
Pepper,Coach,and Henry (a very brave little Maltese)
R Pod 172

The rewards of the journey far outweigh the risk of leaving the harbor...unknown


Posted By: PodPatrol
Date Posted: 16 Apr 2010 at 11:39pm
Very Interesting Perspective on the Pod Sandpiper. The pictures are comforting, and with your added descriptions they become very realistic.
 
This is an excellent view inside the Pod ..... Thanks for the insight, and the pics !!!
 
Thumbs Up


Posted By: tedbear
Date Posted: 17 Apr 2010 at 1:58am
Great shots, but I wish you could show us how the roof is framed - did you get any shots of that part of the process?  Thanks!


Posted By: The Chicken Ranch Ea
Date Posted: 17 Apr 2010 at 3:58am
Superb Post!

-------------
The Chicken Ranch East


Posted By: Sandpiper
Date Posted: 17 Apr 2010 at 9:35am
tedbear
Sorry, I don't have any shots of that to share.  But I can assure you it is done in a structurally sound and similar manner to the side walls.  I can tell you the skin for the front, roof and back is one continuous piece well  supported,  well insulated , well sealed and installed with great care.


-------------
Sandpiper
Mrs.'Piper
Ford 150-[Mini Lite 2104S]


Posted By: popgoesweasel
Date Posted: 17 Apr 2010 at 11:52am
here is the URL to the MPG specs.  The coach is 77" with 8' total.

http://www.heartlandrvs.com/product.html?id=20&name=MPG&type=Luxury+Fifth+Wheels&section=specifications - http://www.heartlandrvs.com/product.html?id=20&name=MPG&type=Luxury+Fifth+Wheels&section=specifications


Posted By: Ratdog
Date Posted: 17 Apr 2010 at 12:27pm
Originally posted by popgoesweasel popgoesweasel wrote:

here is the URL to the MPG specs.  The coach is 77" with 8' total.

http://www.heartlandrvs.com/product.html?id=20&name=MPG&type=Luxury+Fifth+Wheels&section=specifications - http://www.heartlandrvs.com/product.html?id=20&name=MPG&type=Luxury+Fifth+Wheels&section=specifications
 
Thanks for getting that.
 
If the MPG is required to have the triple lights along with the front and rear fender lights to comply with the 80-inch rule, then it seems the Pod would have to have them too. Both have a coach width less than 80" but a total width (including wheels/fenders) wider than 80".
 
If anyone hears a final word on this, please post it here. We're supposed to pick up our pod very soon in Hamilton and I'd like to have them make any required modifications while they still have the trailer. I will also follow up on this issue with Brannon when he calls to let us know our Pod is ready for pickup and will post his response here.
 
Take care,
-- Steve
 
 


-------------

Steve, Anne, and Paige the Rat Terrier
2013 Lexus RX 450h Hybrid AWD
2011 RP-177 (aka: The Circus Wagon)


Posted By: Sandpiper
Date Posted: 18 Apr 2010 at 12:37pm
Originally posted by tedbear tedbear wrote:

The jack does not retract high enough as it is, as many people have reported it scraping the ground (happened to me once, too).  I added a wheel to mine anyway just to test it, and it touched the ground when the camper was hooked to my car.
 
Perhaps if one could cut some of the lower jack post off, it would allow room for a wheel?


tedbear
The boat trailer we had had the same problem with the jack being too close to the ground.  We had a removable wheel which was removed any time the trailer was in tow and re installed before we unhooked from the tow vehicle.  That worked out well for the boat trailer and I plan to purchase a wheel from the jack manufacturer for the R Pod and remove it when we tow the R Pod.


-------------
Sandpiper
Mrs.'Piper
Ford 150-[Mini Lite 2104S]


Posted By: PodPatrol
Date Posted: 19 Apr 2010 at 1:56am
We purchased the Wheel and the Foot from the manufacturer and we're using the foot at the camp. I'm sure the Wheel will be great for moving the Pod on a level surface. For the most part we will be using the foot. Not as snug as I had hoped for, but it don't get more snugger(?) than from the manufacturer.
We have touched the jack once in the driveway. It is close, but so far so good. We too add the foot before detachment, and remove before towing.


Posted By: tabkld93
Date Posted: 20 Apr 2010 at 3:31pm
Awesome photos and story.  Nice work  Thumbs Up

-------------
Todd, Karen & Leah
'13 Surveyor 240
'12 Ford F150 EcoBoost
Former owner of 2010 R-Pod 172


Posted By: wolftone
Date Posted: 22 Apr 2010 at 4:02pm
I recall from an earlier post that the roof is insulated with fiberglass batting, like the walls of a house. Presumably because the rigid-type foam won't make the bend.


Posted By: wolftone
Date Posted: 22 Apr 2010 at 4:10pm

Its is a very useful report, and I thank you also. I hope someone else also gets the chance to do a plant tour with a camera - what an opportunity!

I see from the shot showing the outer walls erected on the base, and with the interior cabinet bulkheads in place but without any kind of roof framing, that the side walls are not structurally connected to each other - so I wonder how the heck is that roof is fixed in place?  To me its a significant question because (theoretically at least) the wracking and twisting forces on the trailer shell can, over the course of time, generate a considerable stress effect (not withstanding the motion dampening supplied by the suspension system).  I guess this is true of travel trailer construction generally, but I still would like to know how the R-Pod roof is pinned on to the edges to those walls. Glue?


Posted By: tedbear
Date Posted: 22 Apr 2010 at 4:43pm
I asked about the roof because I wondered if the studs are aluminum or wood.


Posted By: wolftone
Date Posted: 23 Apr 2010 at 11:02am

If you really look closely at that picture titled "of the final assembly line from station one to a point approximately 3/4 way through the line" you can see that the outer skin of the side shells sticks out proud of the aluminum frame around the edges.  Looking past the trailer in that shot there looks like what might be a pile of curved aluminum frames on the floor, but its somewhat blurry.  These could be roof frames that will be mechanically attached to the side shell frames in some way, but more likely are just preassembled frames for the tent openings.  The "flange" of of fibreglass and Phillipine (Luan) mahogany sticking out of outer walls would cover the edges of the roof frame.  No way of knowing  if they use pre-welded aluminum roof framing modules or if they just insert some wood battens between the walls. 

Also would be interesting to know how the underside of the wood floor is protected from moisture other than by the fabric scrim I see when I look underneath.  If the plywood used for the underside of the the floor base is Luan "mahogany", that is a very rot prone species if there is moisture ingress.  I know this from 20 years as a boat builder (including 4 years in the Orient building large yachts), and 18 years as a full time marine surveyor. 


Posted By: Sandpiper
Date Posted: 23 Apr 2010 at 1:26pm
Guys, I wish I could shed some light on your inquiries about the structure of the roof but I can't.  I would suggest you contact the factory and ask them.  I would suggest contacting the lady that was out escort for our tour and she can either tell you or perhaps she can refer you to someone that can answer your questions.  Her name is Kristin Griffin, phone 574-642-3119 Ext. 213 or e-mail kgriffin@forestriverinc.com  .  You could just call the operator and she could direct you to a person to answer your questions.  I have found the people there very helpful.



-------------
Sandpiper
Mrs.'Piper
Ford 150-[Mini Lite 2104S]


Posted By: wolftone
Date Posted: 08 May 2010 at 2:31am
I did email her, but so far no reply.


Posted By: Sandpiper
Date Posted: 08 May 2010 at 10:04am
Try Susan Thornberg. 

sthornberg@forestriverinc.com

574-642-3119 ext 205. 
She is the warranty person but may be able to tell you who to contact-- beyond that I am at a loss..


-------------
Sandpiper
Mrs.'Piper
Ford 150-[Mini Lite 2104S]


Posted By: dragonfly's r-pod
Date Posted: 23 May 2010 at 10:33pm
Hi Sandpiper I was wondering if you remember if there was aluminum strip in the front and back.  Basically the piece that makes the top?  Thinking about doing a mod but want to be sure.  Thanks Maggie


Posted By: wolftone
Date Posted: 26 May 2010 at 9:58am
I did get a nice email from Kritin Girffin at Forest River, apologizing for not getting back to me abbout my inquiry about R Pod roof construction....but it was just an apology, with no promise of an answer.


Posted By: Sandpiper
Date Posted: 29 May 2010 at 9:15am
Dragonfly's R Pod

Sorry it took so long to answer but we have been houseboating in the Thousand Islands on the St. Lawrence River and were really boondocking. So no internet.   I didn't see any aluminum or any other metal in the front, top or rear of the R Pod.   Hope that helps you with your decision on the Mod..

-------------
Sandpiper
Mrs.'Piper
Ford 150-[Mini Lite 2104S]


Posted By: wolftone
Date Posted: 29 May 2010 at 11:05am
Nevertheless, we still don't know how the roof is constructed and connected to the walls.
 
At this rate, we may never know until an R Pod is destroyed or self-destructs!  How strange.


Posted By: DJBobbbyG
Date Posted: 04 Sep 2011 at 8:13pm
Here is a fairly poor video of R-Pods being built and at the end of it, if you freeze it, you can see the structure for the roof.  The picture is a bit fuzzy, but you can make out some details. http://www.youtube.com/watch?v=O0W9PCL7TZM

-------------
Pulling an R-Pod 177 with a 2007 Toyota 4Runner.


Posted By: brianc1959
Date Posted: 01 Oct 2012 at 5:02pm
Perfect.....  I do wonder how the roof ribbing looks.  Is that similiar?  Picture?



Print Page | Close Window

Forum Software by Web Wiz Forums® version 11.0 - http://www.webwizforums.com
Copyright ©2001-2014 Web Wiz Ltd. - http://www.webwiz.co.uk