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Author Topic: The Birth of a Bus  (Read 5227 times)

SargeW

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The Birth of a Bus
« on: May 27, 2017, 12:17:20 AM »
I am in Red Bay Alabama, at the Tiffin Motorhome factory. Today was the first day of our build of our Allegro Bus 40SP. Tiffin allows owners to follow the build down the assembly line. It was quite impressive. I showed up at 0600 and the chassis had just rolled into station #1.

I was there all day, and by quitting time it was heading to station 6 on Tuesday to put on the rear cap. This process really moves!  I was up close and personal as workers started to assemble the hundreds of parts that will make up this motor home.  There are 4 more days of build before it rolls off the assembly line and heads to paint. I will be here for all 4 days.  I have already taken about 200 pics of the process.  The workers are skilled and professional, and still have time to be quite friendly and informative. 
Marty--
2017 Tiffin Allegro Bus 40SP
Cummins ISL 450 HP/Powerglide chassis
Visit our new travel blog! http://www.mytripjournal.com/rvnchickTNG
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HueyPilotVN

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Re: The Birth of a Bus
« Reply #1 on: May 27, 2017, 12:24:46 AM »
Good for you.  Document the entire build and you will have the greatest rv manuals.
Happy for you.
Bill Waugh
40' Country Coach DP
34' Stacker Trailer, Trailer Toad
Jeep Commander
Mustang Bracket Race Car
35 years on the road

Sun2Retire

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Re: The Birth of a Bus
« Reply #2 on: May 27, 2017, 01:03:19 AM »
What fun.

Boy would I be a nuisance. "How bout if we run couple extra cables here? Can I add this little light there? Did you remember the satellite internet cable along with the wifi and cell booster cables in case I add those? You know what would be cool....?" Etc etc

"Sir. SIR! Give me your hard hat and visitor's badge and step away from the assembly line!"  ::)
Scott
2005 Newmar Dutch Star 3810, Spartan, Cat C7 350 "OURVEE"
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SeilerBird

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Re: The Birth of a Bus
« Reply #3 on: May 27, 2017, 05:02:36 AM »
How very cool Marty. I am jealous. I had a Tiffin once and it was a great RV. I am sure you will be very happy.
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Larry N.

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Re: The Birth of a Bus
« Reply #4 on: May 27, 2017, 06:41:26 AM »
Thanks for sharing that, Marty. You're doing with your bus what I did with our house (over months, not days though), getting pix and being familiar with it inside and out. Enjoy.
Larry and Mary Ann N.
2016 Newmar Ventana 3709 -ISB6.7 XT 360HP
2015 Wrangler Sahara Unlimited toad
Formerly: Trailmanor 2720SL
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Tom

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Re: The Birth of a Bus
« Reply #5 on: May 27, 2017, 06:53:22 AM »
Great Marty. The photos will be invaluable for future troubleshooting.


Meanwhile, keep the photos coming; When you're done, this would be a good addition to our photo gallery. The last time we saw a factory build was Smokey & Sharon's coach:


http://www.rvforum.net/coppermine/thumbnails.php?album=11
« Last Edit: May 28, 2017, 10:02:28 AM by Tom »
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Dvan

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Re: The Birth of a Bus
« Reply #6 on: May 27, 2017, 07:28:39 AM »
What a great experience, I would absolutely love to do that!
Daryll & Erin
2013 Thor Damon Daybreak 34BD bunkhouse
Parker, Colorado

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NY_Dutch

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Re: The Birth of a Bus
« Reply #7 on: May 27, 2017, 08:09:56 AM »
Fantastic, Marty! I'm glad you're getting to witness the "birth" of your new coach!
Dutch
2001 GBM Landau 34' Class A
F53 Chassis, Triton V10, TST TPMS
2011 Toyota RAV4 4WD/Remco pump
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oldwasichu

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Re: The Birth of a Bus
« Reply #8 on: May 27, 2017, 09:35:47 AM »
Great pictures, Marty. Thanks for sharing. And congrats on the new "house on wheels".
Dave & Jeanne
Northern Illinois
2010 Winnebago Journey Express 34Y
Scottish terriers (Angus and Lil)

jor_az

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Re: The Birth of a Bus
« Reply #9 on: May 27, 2017, 04:25:58 PM »
Quote
Meanwhile, keep the photos coming

I second that. I love these photos.
jor
« Last Edit: May 28, 2017, 03:02:04 PM by jor_az »

Betty Brewer

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Re: The Birth of a Bus
« Reply #10 on: May 27, 2017, 09:19:18 PM »
Terry did somewhat the same on our Country Coach build in  1999. The photos Terry took have been valuable when making repairs later.  One comes to understand  why the price is so high on these  vehicles/homes when they watch all the inside  processes.

The workers were so grateful to  Terry  for buying the rig that they were more than happy to answer questions, let him take photos and generally be " in their way."

Enjoy the  process and congrats as I read on Facebook that your Fallbrook home sold again! The  plan just keeps falling into  place!
Betty Brewer

see where we are

SargeW

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Re: The Birth of a Bus
« Reply #11 on: May 27, 2017, 10:47:40 PM »
Thank you everyone! This is truly one of the coolest experiences I have ever had. And since I have already taken over 200 pics, I will fill in a few of the spaces that were covered in the first few pics.
Enjoy the  process and congrats as I read on Facebook that your Fallbrook home sold again! The  plan just keeps falling into  place!

True Betty! We are so excited about the quick sale and offer.  It feels like the pieces are finally falling into place!

Some additional pics from day one.  In #1, if the engine looks close in this pic, it's because it is! This model has a side radiator, so the engine is totally accessible right from the back of the coach. The power plant is the Cummins ISL. It is rated at 450 HP and 1250 ft lbs of torque.

#2 If the tires look big, they are. The Michelins on this coach are 315 80 22.5.

#3 The storage tanks are being set. The white tank on the bottom is the 90 gallon fresh water tank. The black tank on top is the 50 gallon black water tank. It will be joined by the 70 gallon gray water tank next to it.

#4 I opted for two pass through slide out trays in the storage bays. No more struggling to reach the stuff in the middle.

#5 We also splurged on heated floors. The wires in the photo are actually spaced 2" apart and attached to the sub floor. Only wires that will actually provide heat have a silvery sheath to them. Some are plain black wires that are "dummy" wires that are just put in to keep the entire floor surface level for the tile floor that is applied to the top in the next step.

#6 The next step is to apply the entire sub floor with mastic in prep for the tile.

#7 Then one massive sheet of ceramic tile that has been preset on a 1/2" sheet of strand board, grouted, and all the appropriate relief cuts made is lifted onto the chassis by a overhead crane with suction cups and is prepared to be placed into position.

That's it for now! More later!
Marty--
2017 Tiffin Allegro Bus 40SP
Cummins ISL 450 HP/Powerglide chassis
Visit our new travel blog! http://www.mytripjournal.com/rvnchickTNG
Support your local Police Officer, Fire Fighter and Military!

SargeW

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Re: The Birth of a Bus
« Reply #12 on: May 28, 2017, 11:19:17 AM »
Great Marty. The photos will be invaluable for future troubleshooting.


Meanwhile, keep the photos coming; When you're done, this would be a good addition to our photo gallery. The last time we saw a factory build was Smokey & Sharon's coach:


http://www.rvforum.net/coppermine/thumbnails.php?album=11

Absolutely Tom! With 200+ pics already, there is no telling what the final tally will be.
Marty--
2017 Tiffin Allegro Bus 40SP
Cummins ISL 450 HP/Powerglide chassis
Visit our new travel blog! http://www.mytripjournal.com/rvnchickTNG
Support your local Police Officer, Fire Fighter and Military!

jackiemac

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Re: The Birth of a Bus
« Reply #13 on: May 28, 2017, 01:23:00 PM »
Fabulous Marty! Really exciting watching the process, can't wait to see the finished article!
Jackie n Steve - Happy Scottish Travellers

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DWJoyce

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Re: The Birth of a Bus
« Reply #14 on: May 28, 2017, 03:00:14 PM »
Great job posting the pictures! Amazing that you only took 200! I would have a few thousand each day. ;-)

Mile High

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Re: The Birth of a Bus
« Reply #15 on: May 28, 2017, 03:20:24 PM »
That would be a blast - even if it wasn't mine!  love how they heat the floors.
Brad and Dory
2013 Winnebago Itasca Meridian 42E (new to us 2016)
2013 Jeep Wrangler Unlimited Sahara
FMCA 457993 / WIT W170238
Denver, CO

SargeW

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Re: The Birth of a Bus
« Reply #16 on: May 28, 2017, 04:18:46 PM »
Great job posting the pictures! Amazing that you only took 200! I would have a few thousand each day. ;-)

I would have taken more, but the battery on the camera was dying about an hour before quitting time! And I have 3 more build days left!
Marty--
2017 Tiffin Allegro Bus 40SP
Cummins ISL 450 HP/Powerglide chassis
Visit our new travel blog! http://www.mytripjournal.com/rvnchickTNG
Support your local Police Officer, Fire Fighter and Military!

Becks

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Re: The Birth of a Bus
« Reply #17 on: May 28, 2017, 05:46:18 PM »
Congrats on the new Bus Marty, a big move up since the Meridian. Enjoy
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blw2

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Re: The Birth of a Bus
« Reply #18 on: May 28, 2017, 09:13:26 PM »
oh, what fun being able to watch it!
How much tweaking do they let you do on the fly?   Things such as ...."hey, can you move that outlet 6 inches to the right?"
Brad (DW + 3 kids)
13 Thor Chateau 31L Class C on Ford E-450
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BRex

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Re: The Birth of a Bus
« Reply #19 on: May 28, 2017, 10:01:35 PM »


I took a tour of the Marathon Coach factory this last TUE. I was told they average about 18 motorhomes a year. Video/photo documenting that build would take lots of batts and memory. ONE month is allowed for the painting process.
'97 Country Coach Intrigue

SargeW

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Re: The Birth of a Bus
« Reply #20 on: June 02, 2017, 10:46:12 AM »
Bus build continued:

#1 & 2 With the mastic applied, the crane lifts the huge sheet of tile into the air and with the help of a few workers is placed onto the mastic.

#3 & 4 Screws with large fender washers are placed all around the perimeter and in known non-heated areas of the floor to secure the tile sheet to the sub floor. For securing the tile in the center section, the floor is energized causing it to heat up. The worker then walks the floor with a FLIR camera to place the middle hold downs. The box that energizes the floor also has an alarm. If any heat wire is broken, then a loud alarm goes off alerting the worker to the problem.

#5 With the floor in place, all of the plumbing and electrical wiring is pulled through the openings in the tile in preparation of setting the fixtures and appliances.

#6 The shower stall is laid flat and filled with water to test the unit for water tightness.

#7 & 8 Another massive amount of wires to route is at the firewall of the dash board area. Pic 7 is the behind the firewall pic and 8 is the drivers side.  I can't imagine keeping all that wiring straight and hooking it up to the correct place! 

#9 & 10 The preassembled cabinet sections are bought over and set in place on the floor. Workers secure the sections to the floor, and route the necessary wires and plumbing lines to the appropriate fixture.

Stay tuned! More to follow as this was still day one!
Marty--
2017 Tiffin Allegro Bus 40SP
Cummins ISL 450 HP/Powerglide chassis
Visit our new travel blog! http://www.mytripjournal.com/rvnchickTNG
Support your local Police Officer, Fire Fighter and Military!

Kevin Means

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Re: The Birth of a Bus
« Reply #21 on: June 02, 2017, 11:02:41 AM »
You're not at all excited are you Marty? ;D
2011 Winnebago Tour 42QD
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Mile High

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Re: The Birth of a Bus
« Reply #22 on: June 02, 2017, 11:23:08 AM »
Were you able to custom order anything?  (extra cable runs, etc.)  I'd be tempted to jump up there and start adding stuff :)
Brad and Dory
2013 Winnebago Itasca Meridian 42E (new to us 2016)
2013 Jeep Wrangler Unlimited Sahara
FMCA 457993 / WIT W170238
Denver, CO

boatbuilder

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Re: The Birth of a Bus
« Reply #23 on: June 02, 2017, 02:23:11 PM »
Cool.  We used to do the same basic procedures with the boats.  I love watching stuff like that. 
Charlie

Larry N.

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Re: The Birth of a Bus
« Reply #24 on: June 02, 2017, 02:30:41 PM »
Nice shots, Marty, but curiously I only count nine pix.
Larry and Mary Ann N.
2016 Newmar Ventana 3709 -ISB6.7 XT 360HP
2015 Wrangler Sahara Unlimited toad
Formerly: Trailmanor 2720SL
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Tom

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Re: The Birth of a Bus
« Reply #25 on: June 02, 2017, 04:15:48 PM »
Quote
I only count nine pix.

Larry, I count 10, but had to use both hands  ;D
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Larry N.

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Re: The Birth of a Bus
« Reply #26 on: June 02, 2017, 06:59:57 PM »
Larry, I count 10, but had to use both hands  ;D

Odd, I do too, now. But I counted three times this morning and only got nine. Perhaps I'm only firing on 2.535 cylinders...  :o
Larry and Mary Ann N.
2016 Newmar Ventana 3709 -ISB6.7 XT 360HP
2015 Wrangler Sahara Unlimited toad
Formerly: Trailmanor 2720SL
  de N8GGG

SargeW

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Re: The Birth of a Bus
« Reply #27 on: June 03, 2017, 12:51:07 AM »
You're not at all excited are you Marty? ;D

How could you tell Kev!  Just like a little kid at Christmas!
Were you able to custom order anything?  (extra cable runs, etc.)  I'd be tempted to jump up there and start adding stuff :)

Oh yeah Brad. We deleted some stuff we didn't want, changed some furniture, and even got the lead carpenter to custom make some cabinetry for us!  As long as you don't get too crazy, they can be real easy to work with. 

I had the carpenter modify a sliding shelf unit under the sink, and since Diane wanted more counter space I eliminated a recliner chair and had the carpenter build another counter top area using the same cabinetry wood and even a matching solid surface top!  Tiffin worked with me and we just traded off the recliner for the labor and counter top so it didn't cost me anything out of pocket.   


Odd, I do too, now. But I counted three times this morning and only got nine. Perhaps I'm only firing on 2.535 cylinders...  :o

It can happen Larry. I have been running on red line for about 3 weeks now!
Marty--
2017 Tiffin Allegro Bus 40SP
Cummins ISL 450 HP/Powerglide chassis
Visit our new travel blog! http://www.mytripjournal.com/rvnchickTNG
Support your local Police Officer, Fire Fighter and Military!

Larry N.

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Re: The Birth of a Bus
« Reply #28 on: June 03, 2017, 06:53:55 AM »
Quote
It can happen Larry. I have been running on red line for about 3 weeks now!

True, Marty, but I don't have the excitement and anticipation of a new coach to blame.  ;D ;D
Larry and Mary Ann N.
2016 Newmar Ventana 3709 -ISB6.7 XT 360HP
2015 Wrangler Sahara Unlimited toad
Formerly: Trailmanor 2720SL
  de N8GGG

Mile High

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Re: The Birth of a Bus
« Reply #29 on: June 04, 2017, 09:20:13 AM »

Oh yeah Brad. We deleted some stuff we didn't want, changed some furniture, and even got the lead carpenter to custom make some cabinetry for us!  As long as you don't get too crazy, they can be real easy to work with. 

I had the carpenter modify a sliding shelf unit under the sink, and since Diane wanted more counter space I eliminated a recliner chair and had the carpenter build another counter top area using the same cabinetry wood and even a matching solid surface top!  Tiffin worked with me and we just traded off the recliner for the labor and counter top so it didn't cost me anything out of pocket.   

Awesome!  Good move on the carpenter, that is hard to do after its built (matching wood, etc)
Brad and Dory
2013 Winnebago Itasca Meridian 42E (new to us 2016)
2013 Jeep Wrangler Unlimited Sahara
FMCA 457993 / WIT W170238
Denver, CO

 

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