Airstream, Inc :: Tour: Part 2

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	Shell Assembly To continue the tour, I'd like to show you how shell assemblies are made. Let's start with the floor. Airstream floors are made from 5/8" tongue and groove or OSB flooring . Right now Richard is fastening aluminum channels to the floor and shell assembly. Richard has worked here for over 19 years and really knows what he is doing. Brad makes sure that the slots in the channels embrace and protect the edge of the wood floor — providing weatherproofing and strengthen the area where the floor and shell are joined.
	5 Assemblies The classic trailer shell is constructed of five separate assemblies: the roadside and curbside side sheet assemblies, the front and rear end assemblies, and the roof assembly. The assemblies are attached with aluminum aircraft rivets on a steel fixture. Then thermal barrier bonding tape is used to create a thermal break between the ribs and the aluminum sheets. This helps control condensation and the transfer of heat or cold from the outside environment.
	Shell Stretch Forming The end shell segments are stretch formed on a mold for each segment, trimmed and punched for assembly.
	Ends Meet Floor The 7 front and rear end assemblies began as flat sheets and are stretch formed by a hydraulic press. Then the different parts are riveted together and the end assembly and the floor assembly are placed on a level platform. Finally, the ends are mounted to the plywood floor using bowed floor channels.
	Roof Construction Here we see the aluminum sheets used for the roof assembly. Each sheet has been coated with white pre-baked enamel paint. This paint reduces the trailer's temperature up to seven degrees, requires no maintenance, other than normal cleaning and waxing, and prevents black streaks from forming on the sides of the trailer. The aluminum sheet, along with the other roof assembly pieces, are riveted together and holes for the roof air conditioner, ceiling fans, and bath fans are made. Q: My friend accidentally put his foot through the roof of his trailer. This roof looks pretty strong. A: Indeed it is. Airstreams are given extra strength by using structural I-beams and U channels. This added strength allows you to walk along the rivet lines on the roof of our trailers without worrying about "dropping in" on someone inside.
	Rivet All Together Watch how those hoists are guiding the roof and side sheet assemblies over the floor structure. Once they're in place, all five assemblies will be riveted together — forming a classic Airstream trailer shell. Dan uses aircraft routers to cut holes for the side windows, then he rivets the windows into place. The routing platform is where holes are made for the main door, the water fill door, and the access doors. Then the aluminum channel around the wood floor is hand riveted to the shell.
	Flying Cloud For many people, this is the favorite part of the tour. Take a look at the hydraulic jacks carrying the chassis overhead. Now those electric hoists are lifting the shell assembly off the routing platform. Maybe that is where the Flying Cloud got its name.Using bolts, Gary and Dale are fastening the two pieces to the steel cross members and outriggers of the chassis. Pretty exciting eh?
	Doors etc.. After the trailer is pulled off the leveling jacks, the main door, access doors, roof air conditioner, TV antenna, and electrical wiring are installed in the next few production stations. Q: What are they doing over there? A: Ah, they are applying a high-grade sealer to all of the interior seams. After the sealant is cured, the shell will be fully protected from the elements. Now let's move on and see how the finishing touches are made to the exterior of the shell.
	Trim & Taillights At this station, the exterior trim, taillights, and graphics are added to the exterior shell construction. Then our Group Leaders go over the trailer with a fine-toothed comb. If even the slightest thing appears to be out of place, our production personel make it right before the trailer is allowed to move on.That reminds me of the time when Wally was conducting one of his inspections. He noticed that an over-head locker was not quite level. He pulled the thing right off the wall. Then he called the foreman and cabinet hanger over and calmly yet firmly said "now see that this is done and done right". Believe you me, they never made that mistake again. Wally sure did have a way with words.
	Water Testing Once the exterior shell is inspected and completed, every Airstream trailer is rigorously checked with our high-pressure water tester. We rarely find any leaks, but when we do, the leaks are fixed and the trailer is tested again. On hot days, you'll see a lot of the workers taking their breaks around this machine. Go figure.