CENTER: With the lamination layers now completed, the team pushes the roof through the pinch roller. After the pinch roller, the adhesive needs several hours to fully cure.
RIGHT: The next morning the same lamination team will rout the frames they laminated the day before. These side walls had been completed a few days before our arrival and were waiting for the camper production line.
LEFT: In Adventurer’s cabinet shop, Francisco Barrera was using a pneumatic framing table. Framing tables allow Adventurer to screw together their cabinetry at precise angles in pre-drilled holes which hide the screws.
CENTER AND RIGHT: Later we saw Francisco preparing to laminate a set of cabinetry walls. After building and glueing the walls, the cabinetry walls are placed into a press where the glue is allowed to set under pressure. This lamination process dramatically increases the strength of the cabinetry walls.
Rather than have a dedicated quality control check only at the end of the production line, Adventurer has a team member who walks the entire production line full-time and checks the quality of the campers throughout their production.
Camper production moves fast, but it’s at a pace where one person can walk a camper production line several times an hour and see how each station is doing. We know this because that’s exactly what we do when we’re on a camper production line.
As we walked up and down the Adventurer production line, we saw Miguel Garcia here, there, and everywhere checking each station along the way. And everywhere he went he had his red squawking tape at the ready.
LEFT: In this photograph, Miguel is inspecting a fiberglass front nose on a 950B and has found a blemish in the fiberglass. Notice he’s not only looking with his eyes but also running his fingers along the material to find imperfections.
CENTER: At the other end of the production line, Miguel is observing the laminate flooring installed on an 80W. Here he was making sure there were no air bubbles in the laminate as they are difficult to remove further down the line.
RIGHT: We just never knew were we would find Miguel. In this photograph he’s fixing some basement screws in a 80W that were not quite straight. Like any good quality control professional should be, Miguel was a little neurotic about quality. If you look closely at this photograph you can see that he even wears the red squawking tape around his wrist.
LEFT: Duct taped to the front wall of every truck camper on the Adventurer production line is what Adventurer calls a line traveler. A line traveler is a packet of papers that include a build sheet, production checklist, and quality control checklist.
Note that this unit was ordered without a Fantastic Fan as noted by the red all-caps writing that says, “NO FANTASTIC FAN”. Whoever ordered this camper, no Fantastic Fan for you.
CENTER: The production checklist is where the production team signs off on each and every step during a camper’s build. This allows Adventurer to maintain accountability, discover problems, and find opportunities to improve quality control. The production checklist also tracks the model and serial number for every component going into a camper. A complete copy of the line traveler for every camper is kept at Adventurer so that quality control can be continuously monitored and improved.
RIGHT: Finally, every line traveler also serves as a quality control checklist. Miguel uses the quality control checklist to sign off on every aspect of quality control as the unit moves down the line. Other production line team members also sign off on every unit.
LEFT: Next to the lamination table, Alberto Lopez is responsible for cutting the foam insulation using a hot wire cutter. This allows the foam insulation to be cut precisely for a tight fit with Adventurer’s wood and aluminum camper frames. The wire is quite hot as you can see from the puff of smoke above the insulation.
CENTER: After the wall components are laminated, the sections are routed out for the production line. Here Cy Mullen is routing a wing wall a few feet from the lamination table and pinch roller.
RIGHT: Once the plumbing and gas lines are installed on a camper, they are checked using pressure tests. In this photograph, Juan Ortiz is testing a camper’s plumbing and holding tank system to make sure it can maintain pressure. Any drop in pressure could mean there’s a leak somewhere in the holding tank system.
LEFT: Before an Adventurer’s sidewalls are installed, the interior cabinetry, plumbing, electrical systems, appliances, and molded fiberglass bathrooms are installed. This photograph was taken about a third the way down the production line and shows a cross section of a camper before the passenger-side wall is installed. At the front nose of the camper, Alberto Nateras is installing carpeting in the overcab.
CENTER: Slide-outs are manufactured on a parallel production line to the main camper production line. Here Anthony Niemann is completing a double bunk slide for a 950B. The 950B is the only camper on the market to feature a bunk slide and is well suited for families with children.
RIGHT: In a room just off the end of the production line, Jerry Guzman manufactures the head knockers and valances for Adventurer campers. Adventurer brings as many things as possible in house to further drive down costs and improve quality.
Adventurer has a clever and efficient way of hoisting a camper roof onto the top of a camper on the production line for installation. The process begins by placing metal inserts with hooks in the places where Fantastic Fans will later be installed. With the inserts placed, the roofs are connected to a crane in the ceiling that then lifts the roofs up and over a new camper. As the roof makes it’s ascent, the roof installation team guides the roof gently into place on the new camper. With the roof in place, the roof team then screws the roof down.
LEFT: With the roof installed, the roof team takes over to install the TPO skin, vents, and other features onto the roof. In this photograph, Danny Ontiveros (left) and Steve Vosberg (right) install the roof vents and complete the TPO roof installation.