Factory Tour
A tour of our Toy Hauler and Trailer factory in Riverside, CA (located about an hour east of Los Angeles) and the process of building a Toy Hauler. The factory is a separate company and facility, but you are more than welcome to take a tour - just schedule an appointment with Dune Sport directly. |
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The Chassis is either ordered and built locally, or custom-welded on-site.
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The chassis is almost complete |
The floor is made up of 3/4" oriented strand board (OSB), but underneath, a waterproof Luaun underlayment fabric is layed out to protect the wood from rot and water damage. |
Excess fabric is left around the perimeter of the floor, which at a later time is folded up to protect the floor even better. |
The vinyl floor is layed down next in a single piece - covering the entire Toy Hauler floor. Since the one-piece flloor is layed down before the walls are put into place, this eliminates any seams where water could seep into the floor. |
A view of the vinyl floor now cut and laid into place. |
The tailgate is assembled separately and mounted to the chassis. |
Notice the strong reinforcements made in the tail gate - this area will become the back of the latches for the tailgate. |
The walls are then assembled separately using pre-made templates. |
Luaun plywood, a water-proof and fire-resistant material imported from Indonesia, is glued and stapled into place on the interior-side of the walls. |
A completed interior wall - complete with cut-outs for door, windows, etc. |
The wall is mounted to the chassis. |
Strong reinforcements are made throughout the walls, specifically for how they will be used on the Toy Hauler. These wood reinforcements for example are for mounting the dinette and couch. |
Additional reinforcements. |
Additional reinforcements. |
The underbelly is flipped up and stapled to the exterior side of the wall, creating a completely sealed floor. |
D.O.T. tubes are installed as channeling to protect all wiring against accidental shorting. |
Corners are reinforced for maximum support and durability. |
A close-up of a reinforced corner. |
A view from below of the sealed underbelly. |
On the inside of the wheel wells, preparations are made to seal the area. |
A one-piece moulded wheel guard, ready to be mounted inside the wheel well. |
The wheel guard is mounted inside the wheel well. |
Molded, plastic wheel wells, which are completely rust-proof, are mounted to give a better seal and cleaner look to the Toy Hauler. |
The underside view of a sealed wheel well. |
R-13 Insulation is hand-cut and placed within the studs. |
The cabinets are built ready-to-install. |
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The cabinets are mounted inside the toy hauler. |
