From the leadership team at Northstar Campers comes an industry first; an all-composite truck camper shell imported from China and outfitted, finished and sold in the United States. Here’s the full story behind Star RV Products.

Star RV Products is a new venture from Northstar Campers, offering an all-composite truck camper line unlike anything currently available in North America. The process begins with the composite shells being manufactured and assembled in China. The composite shells are then imported to Northstar’s facility in Iowa. There, the products are either sold as composite shells or fully outfitted into finished campers before being shipped to dealers across the country.

While unassembled camper kits from China and completed campers from Europe have been imported to the United States before, this marks the first time fully assembled truck camper shells have been built in China and brought stateside for final completion and sale.

When Rex Willett, President of Northstar Campers, first shared this concept with us, we knew it would spark questions among truck camper owners and the industry insiders. Why build campers in China instead of the United States? Is Star RV Products’ overseas manufacturing approach healthy for the domestic truck camper market? And how does it square with ongoing concerns about Chinese imports and tariffs?

In the following interview, Rex answers these questions and shares the full story behind Star RV Products’ new lineup.

Above: Completed Star shells in Cedar Falls, Iowa, all photos courtesy of Star RV Products

In April of 2007, you made a statement about China in your first TCM interview:

“The RV business as a whole is totally oblivious to what’s going to happen. They can put two or three travel trailers or two or three truck campers in a container and ship them from China for about four thousand dollars. It’s a recipe for disaster. This will either force manufacturers to partner with the Chinese or raise tariffs. What the Chinese want to do is completely pick our mind of our knowledge and take the RV industry, an American icon, away from us. So many American families have gone through tough times, and they can take it all away from us in two to three years. And they can build quality.”

Eighteen years later, why are you launching a new line of campers made in China?

I was rather prophetic eighteen years ago when discussing China, wasn’t I? Over the past eighteen years, so many American RV parts suppliers have turned their manufacturing over to China for cost savings. There are only a small handful of suppliers, like Torklift International, that try hard to stay domestically produced.

For the past several years, every RV manufacturer has assembled their line of campers with 80% or higher Chinese-made parts. From the refrigerators, furnaces, water heaters, hinges and hardware, screws, wire, fiberglass siding, all electrical connections, batteries, interior and exterior lights, water lines, electric jack motors and brains, water fills, electrical inlets, windows—almost all the ingredients for an RV are made in China.

Our factory is filled with boxes from American suppliers, all labeled “Made in China”. That has all happened in the past eighteen years. All American and Canadian OEM manufacturers are simply assembling campers with Chinese parts and appliances.

This is what prompted me to learn more and to team with a knowledgeable supplier in China already making RVs. Northstar is known for making a rugged and warm quality wood-frame camper, but we really don’t have the space to launch a composite laminated camper. Teaming with a company already doing it—and doing it well—made sense.

The Star RV camper also features all-aluminum powder-coated cabinetry with solid steel fasteners. Instead of us finishing a wood-frame camper, we are finishing a composite shell camper. We still install all the appliances, run the gas lines, and finish the units just like we would a Northstar camper shell.

Above: A completed Star Comet

Do you still believe Chinese imported truck campers represent a potentially existential threat to domestic truck camper manufacturers—including your own Northstar Campers?

You could sense that threat from my statement clear back in 2007, and the United States RV parts suppliers had already teamed with Chinese manufacturers during that time. But if a person isn’t aware of what is happening, you really have blinders on. If we could not source parts from China, it would bring the RV industry to a screeching halt. That’s simply the reality of it.

Years ago, I remember laughing at someone who told me that the Chinese were going to take over our furniture business. I thought it impossible and a feat that could not be done. Now they own that business flat out.

So I think it’s wise to plan for future Northstar growth, but also grow a relationship with a strong Chinese firm to diversify and grow a new segment into the market.

Above: The Star Comet fits inside the tailgate of a standard short bed

Given the unpredictable nature of international tariffs, are Chinese-made truck campers viable?

Yes, even with the tariffs, Chinese-made truck campers are viable and competitively priced because all the supplied parts and products are already made there. All the imported RV parts are also tariffed, so the costs will go up for all North American manufacturers accordingly.

There will be readers in the United States and Canada who would prefer that Star RV truck campers were made in North America. Why not build Star campers domestically?

I think everyone would prefer that. We would also prefer that all of the RV parts be made here. Like I stated before, every domestic RV manufacturer uses Chinese-made products and simply assembles campers in different designs.

By importing the shells with the cabinets installed, we can bring Star RV campers down the same line the Northstars are brought down. And by installing the same proven appliances we do for Northstar, the warranty is the same. This approach allows us to control the quality of the build, and allows us to interject Star units on the same Northstar line.

“Every domestic RV manufacturer uses Chinese made products and simply assembles campers in different designs.”

Did you consider other ways you could have accomplished the same competitive advantages without importing campers from China?

Not really. The investment cost to obtain shells versus purchasing more land, building another facility, buying all the lamination equipment, paying the taxes on the facility, insuring the facility, waste removal, and all the upkeep really doesn’t make sense.

You would have to sell thousands of campers to even break even on the dollar amount invested. That’s a huge gamble I don’t want to take. Now I can use their facility—which has tremendous capabilities—craft the shell I want, and then finish the units here on our Northstar production line.

Our production team will go from a Northstar right into a Star camper and start running gear and installing appliances. There’s still a large investment to start another camper line, but importing the shell and completing the units in Iowa significantly reduces the overhead cost.

How do you handle quality control with a camper made 6,000-plus miles away?

The Star RV warranty is the same as a Northstar camper. Our shell warranty is two full years, and all the appliances have their own one-year warranty.

Above: A photo from Rex’s visit to the factory in China

Have you been to China to visit the factory where the Star RV camper shells are made?

Yes. I first talked with them and ordered one container of three different samples. I wanted to see the quality first before even attempting a visit. Once I saw their capabilities, I went to China and visited the factory.

It was a very impressive, seven-story facility. Housing for the workers is a seventeen-story modern brick apartment building right on-site. Most of the workers live long distances away and take the high-speed rail trains to go back and visit family every couple of months. They work seven days a week and ten-hour days.

There’s a twenty-four hour cafeteria onsite, soccer courts, and basketball courts. Everything is nice, neat, and organized. The office building is also five stories, and each floor houses a different department. Two floors were empty as they say they are going to double the size of the production facility in the next two years to double output.

The first thing I saw when I walked into their production facility was huge metalworking departments with stainless steel laser cutting machines, presses, and brakes. The same facility also makes all the stainless steel chicken rotisseries you see in Walmart, Costco, and many supermarket chains. I asked them if they sold directly to these companies, and he smiled and said, “Americans don’t like buying from the Chinese, so we sell to a distributor in Canada, and they sell them for us.” Let that sink in.

This company also produces large aluminum boats, pontoon boats, deep-V fishing boats, submarines, travel trailers, teardrop trailers, and many different styles of truck campers—from fiberglass molded pop-ups and hard sides, to traditional pop-up campers and flatbed truck campers.

The week before I got there, Camping World was there commissioning them to produce units. About eighty-percent of their RV production is going to Australia, brought in under Australian company names—completely finished and shipped. They have taken a huge chunk of the Aussie market.

All of their departments were in-house: fiberglass molding, lamination, metalwork, aluminum work, aluminum and steel welding, in-house powder coating, sewing, design, and a carpeted showroom that was 60,000 square feet. When I walked into the showroom, you first needed to click your shoes in a machine that covered your shoes in protective plastic booties. It was massive, with all the units they produced on display.

Under the office buildings is their parking garage. Twenty-five of the seventy-five spaces had high-speed electric car charging stations. It was a lot to take in. What really impressed me about the factory was how well it was managed, how clean it was, and how versatile and organized it was running.

Above: Rex Willett working on a Star camper design

Let’s back up a bit. Tell us about the design and development process for Star RV truck campers.

The design process is similar to here, just at hyperspeed. They employ twenty-five full-time engineers and have all the latest programs for design work. I would start with a sketch, and they would take it from there.

In meetings, the engineers would make immediate changes to what we were discussing on a large screen, which made it easy to adjust rapidly and advance the whole process. Purchasing agents were also part of the meetings, as I wanted certain quality products used, so they could source them—which they did.

Did you see a physical Star camper prototype before you went to production?

Yes, and I only liked one of the prototypes they sent me. That’s where the Comet came from. We made many changes from the first prototype, and so many improvements. They adapt to every single request I make in quick order and are a great team to work with.

“After we introduce the two new units this fall, the plan is to expand the lineup with even more models for the 2027 model year.”

Will Star campers include both pop-up and hard side models?

There are two more Star models in the works that we will announce in the September to October time frame. One is a larger, self-contained hard wall, and the other is a pop-up camper with an electric lift. Both will be well equipped. After we introduce the two new units this fall, the plan is to expand the lineup with even more models for the 2027 model year.

Above: Welded aluminum camper frames at the China factory

Do Star campers have a frame or exoskeleton?

There is some aluminum framing in the Star campers. The floors are honeycomb plastic, and the walls and ceilings are 1.5-inch-thick dense foam with 1.58mm fiberglass interior and exterior panels.

How do Star camper shells handle thermal transfer?

They do well, but the heavy aluminum joining corners transfer heat and cold, as all aluminum-frame or composite campers do. You cannot change physics.

For the record, Star camper shells are 100-percent composite panels? Is there any wood in the Star camper build?

There is no wood in the Star Comet camper or Star shells build. We make a plywood bed filler so the dinette can be made into a bed, but it’s not structural.

Above: A cross-section of Star RV composite

Once completed, do the roof and side seals on a Star camper composite shell need to be maintained?

The panels are adhered with a black windshield and body sealant. We go over the top with a clear seal, just as an extra layer of security. It’s always wise to inspect seals every year, as all RVs require maintenance, lubrication, waxing, winterization, and cleaning.

Above and below: The Star Comet cabover and main living area

When a Star camper shell arrives at Northstar from China, what does it have, and what’s missing?

The Comets have the cabinetry, lighting, countertops, cushions, mattresses, and most of the wiring run. They also have the grey and fresh water tanks installed. The fresh water tank on the Comet is a twenty-five-gallon heated and insulated stainless steel tank with a cleaning access port.

Above: The Star Comet fresh tank access port for cleaning

The tank also has a float gauge to monitor how much water you have. The grey tank is welded aluminum, also with a float gauge.

Above: The Star Comet kitchen, dinette, and main living area

We install the appliances, air conditioners, water lines, gas lines, batteries, battery shunts, cooling fan, thermostats, roof vents, cabover Skyview vents, and the Happijac jacks.

Above: The Star Comet comes with a 280Ah lithium battery and an inverter standard

Above: The Star RV control and monitor panel

We use the same appliances in a Star that we use in a Northstar. Then we test the equipment and water test the unit.

Above: Star RV is using many of the same components found in Northstar Campers

Are you selling Star campers direct or through a dealer network?

Star RV campers will be sold through dealerships. We are seeking new dealers for the Star product, but existing Northstar dealers will have the first opportunity to commit to the line.

Some of our dealerships selling Northstar, like Trailer World of Colorado and Scatt Recreation in Sacramento, have already committed to representing Star in those markets. If a Northstar dealer does not want to carry the Star Camper line, it’s not mandatory.

We will add dealerships to the Star RV Products website as time moves along. We encourage any dealer to contact us to learn more about becoming a Star truck camper dealer, or a Northstar dealer.

Above: A Star shell on a Jeep Gladiator

When will Star campers be available at dealers?

Trailer World of Colorado and Scatt Recreation have Star RV campers now. We are starting the dialogue with all Northstar dealers now.

Above: The Star Comet floor plan

We will have a follow-up interview to go through the individual Star camper shells and Star Comet. In the meantime, can you give us a preview of the base MSRP for the initial lineup?

The Star RV shell units for the do-it-yourself guys retail at $17,900, including four insulated windows, interior lights, and a screened entrance door, plus freight and dealer prep.

The Comet has a retail price of $36,900 plus freight and prep. The other Star models coming will range from $29,000 to $46,000 and be very well equipped like the Comet is.

What is the warranty for Star RV truck campers?

It’s two years on the body and twelve months on all the appliances.

“I want to grow Northstar and Star RV Products by expanding the line, offering unique features, and offering more floor plans.”

What’s your vision for Star RV Products five years from now? Where are you going with this brand?

I want to grow Northstar and Star RV Products by expanding the line, offering unique features, and offering more floor plans.

Above: The Star RV 12-volt refrigerator in a Star Comet

In addition, the Star RV brand will offer appliances and products directly to the public at great prices. Currently, we only have two 12-volt compressor refrigerators for sale on the site, but we will be adding flat-panel acrylic insulated windows in several sizes, entrance doors, Skyview insulated vents, power inlets, cords, adapters, glass-top sinks, and cassette awnings—all at prices that are affordable.

Above: Pleated window shades in the Star Comet

We also want to sell other OEM manufacturers these same products to help make campers more affordable. The prices will be fantastic on all the products coming to the site, and we want to set a new standard for quality parts at never-before-seen pricing. Any OEM manufacturer can contact me, and we can quote them insulated windows, screen doors, faucets, sinks, awnings, refrigerators, and more that we have in inventory to save them money with higher-quality products. We can help them not increase the cost of their campers, so it’s a win-win for the industry and the consumer.

Is there anything about Star RV Products—the company, the concept, or products—that you would like to add?

I believe Star RV Products will expand our offerings of great products at great prices. We invite you to contact Billy Mackaill, our sales manager, at 602-524-7629 to learn more about Star RV Products.  Feel free to check out our Star Comet PDF.

For more about Star RV Products, visit their website at starrvproducts.com.  Click here for a free Star RV Products brochure.