Red Bay, AL 2009

After we left the Memphis area, we stopped in Red Bay, AL, like we did last fall. Red Bay is the home of Tiffin Motorhomes, and we wanted to take another plant tour to see the new 2010 models. Even though we weren't having work done on our motor home like last year (click HERE to read that post), we stayed at the Allegro Campground again because it's conveniently located right at the edge of town and it's cheap.

The Allegro Campground has full hookups, 50-amp electric, and free Wi-Fi. The campground is built at an old airstrip, so it is all gravel, except for the main campground road which is the old asphalt runway. The repair facility, which has 40+ repair bays, is right next to the campground. The sites are pretty close together, and there is a fair amount of commotion between 7:00 and 8:00 AM when everyone is taking their coaches over to the repair facility. But, like we said, the campground is convenient to town, it's cheap ($10 a night), and it's also fun to see all the Tiffin motor homes all lined up in a row and to talk to some of the other Tiffin owners. The photo below shows our site at the Allegro Campground.

The Allegro Campground does not accept reservations, and it fills up by Sunday night or Monday, especially during the snowbird migration, with people coming in for service. Therefore, we timed our arrival for Saturday to avoid the rush and found the campground only about half full when we pulled in around noon.

We headed into town to Tiffin Motorhomes on Monday for the 10:00 AM tour. There is also a 2:00 PM tour; but since the workers go home at 2:30, there isn't as much going on during the afternoon tour. The tour starts at the visitor center outside the main gate.

Red, who is now 83 years young, is still leading the tours. He is very well informed about Tiffin Motorhomes, and he is sharp as a tack. If someone makes a joke, he will pick up on it immediately and join in with some good-natured banter of his own. He knows all the models and all the floorplans; and if someone asks a question to which he doesn't know the answer (which is rare), he will usually find the answer by the end of the tour.

As we walked through the plant gate, we were heartened to see many more motor homes sitting around than there were last year and to see a good many employees' vehicles in the parking lot. Back in 2007, Tiffin built 13 motor homes a day; but when we visited last year when fuel prices were so high, they were only building 6 motor homes a day and they were only working 4 days a week. This year, even with the weak economy, they are working 5 days a week and producing 7 motor homes a day. There are still a lot of lay-offs, but things are on the upswing and they said the number of motor homes will soon be increased to 8 a day. The next photo is the view inside the main gate. Motor homes waiting for final inspection are in the distance, and a portion of the employee parking lot is to the left.

The tour includes only the main assembly building. The chassis shop welds the beams that support the floor and other brackets and components onto the chassis. The chassis then enters the main assembly building under its own power (notice the temporary seat to the left) where workers begin installing wiring, holding tanks, storage bays, and plumbing under the floor.

Workers then install the floor, the carpet, and the tile. Wires and plumbing are fished up through openings in the floor.

Interior walls and appliances go in next. More wiring and plumbing are added.

In another area of the plant, exterior walls are being fabricated. Slabs of polystyrene foam are cut by CNC (Computer Numerical Controlled) routers to hollow out slots for the aluminum frame.

In the next photo, pieces of pre-cut, square aluminum tubing are being installed into the slots in the foam at the table on the left. On the right, the pieces of aluminum are being welded into a strong, solid frame.

After the frames are welded, an outside skin of fiberglass and an inside skin of thin, wallpaper-covered plywood are laminated to the foam. Workers then cut openings for windows, doors, and slide-outs in the walls. The completed wall leaning against the ladder in the photo below is waiting to be hoisted into place on the motor home behind it.

A foam ceiling assembly is fastened down on top of the walls in the bay with the overhead walkway to the left in the photo below. A one-piece, molded fiberglass roof (stacked on the floor) is lifted by the overhead, yellow-frame hoist with vacuum-powered suction cups and placed on top of the foam.

Workers then install slide-outs. A few, smaller Tiffin motor homes have two slide-outs. The rest have at least three slide-outs, and most have four.

Next, the workers install storage bay doors, interior cabinets, furniture, trim, front and rear end caps, and miscellaneous items. When the assembly is complete, the motor homes are driven a few miles north to Belmont, MS, to the paint shop. All Tiffin motor homes get full body paint. The units are then returned to Red Bay for final cleaning and inspection.

After our plant tour, we stopped at La Estancia Mexican Restaurant, which is right down the road from the campground. The food was good, although not as good as our favorite Mexican restaurant Cozumel back in Greensburg, PA; and prices were reasonable. We both had Lunch Special #1, which consists of a chili relleno, a taco, salad (guacamole was extra), and refried beans. Margery substituted rice for the beans. In the next photo, Margery is about to take a bite of her taco.

When we got back to the Allegro Campground, we stopped in at the surplus store. Tiffin sells furniture and other components leftover from older models in a warehouse-like building adjacent to the campground and repair facility. We didn't find anything we needed this time, but you never know what they may have.

We stayed in Red Bay a week, but other than taking the plant tour and eating out once we didn't do much. We stopped at the local grocery story to pick up a few necessities; Margery got a haircut, read, and did some budget work and travel research on the computer; and Paul ran over to the local hardware store, washed the car and motor home, and did a little puttering around the motor home. And to help with the puttering, all the men on the Tiffin plant tour got a gift of a 10' tape measure with the Tiffin logo. It was the best promotional gift he could have gotten. You know men and their toys...big and small.

From Red Bay, we had a short drive to a new destination where we planned to relax some more. Look for our next post, and we'll tell you all about it.