RV Tracker: How a Jayco RV is Built

Are you curious as to how we build each RV? As with any product, manufacturers have a variety of ways to build RVs. Most manufacturers utilize an assembly line process. Jayco uses this process, but also adds extra steps to improve product quality and durability. Bear in mind that some manufacturing steps vary between towable and motorized products. We’ll be highlighting the process of building a towable trailer.


First, we start with the frame. Unlike most of our competitors, we custom build our frames for each and every floorplan, which adds to the overall integrity of the unit. Next comes the floor, made of a core wooden frame. On top of the floor, we install tongue and groove plywood, providing a solid, secure foundation for each RV.


The next step is to flip the frame to install the holding tanks, propane lines, wiring, fiberglass insulation, and the underbelly cover to protect the unit from road debris. After the underbelly is installed, we install the stabilizer jacks, axles, tires and rims. With this complete, we flip the unit back upright and put the unit in carriage dollies. This increases efficiency and ease as the unit goes down the line, allowing our craftsmen to push the unit from station to station.


Next comes the cabinetry. We are very proud of our Amish craftsmanship.  We install real, hardwood cabinetry, which is built in a mezzanine above the line. This saves floor space and allows our craftsmen to slide the cabinets down a shoot to be installed in the unit.

Once the frame is built and cabinetry is installed, next come the walls. First, we frame each wall and construct the interior wall panels. Once the framing is complete, we can begin installing insulation. Unlike most of our competitors, we glue the insulation to the interior wall to prevent sagging over time. Next, we attach the aluminum to the studs.


Once the walls are complete, we can focus on the roof. We run wiring through the roof, install fiberglass insulation, and top it with plywood decking. Jayco installs its Magnum Truss roof, taking extra steps in the production process. This results in a roof that is 50% stronger than the competition. Once the roof is complete, we cover the roof with a one-piece rubber membrane to cover seams and provide extra protection against moisture and leaks.


The final step is what we call the “Final Finish” station, where we implement 29 function tests regarding the electric, water, and propane systems. Our goal is to provide you with a quality unit so your family can enjoy it for generations while creating generations of family fun.

If you’re ever in town, stop by our Visitor’s Center to take a tour!

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