Explore Thor Motor Coach’s Lamination Process

All of our motorhomes are engineered using the best combination of aluminum, steel and fiberglass.

The walls and roof are constructed from aluminum, which provides a strong, yet lightweight skeleton to support the overall house of the motorhome.

Our floors are built from steel. The heavier steel construction helps lower the overall center of gravity of the motorhome, while providing an excellent platform to help insulate the interior of the RV from road noise.

The insulation within the walls roof and floor is low-density polystyrene foam. The insulation is form fitted to all structural areas to provide protection from the exterior elements.

The sidewalls are finished in fiberglass. Large flat sheets of fiberglass are laid on a lamination table to be prepped and boned to the aluminum structure.

A large glue applicator runs beads of adhesive every inch down the length of the structure, to ensure 100% coverage. Then the lamination process takes place. The entire walls, roof and floor are inserted into an individual lamination bed where air is removed and pressure is applied, which causes the adhesive to flash – this process is also known as vacuum bonding. This flashing permanently bonds all the layers together, providing the optimal structure to build a motorhome.

With the lamination process complete, a final rounding of all cutouts in the structure is performed. All openings in the walls and roof are framed in aluminum; while the floors are framed in steel. This extra step ensures the openings are always sized correctly, so items like windows, vents and entry doors will fit each and every time.

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