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Chassis Fabrication and Customization

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Newell Coach Factory Tour: Hand Built In Oklahoma! (2+ Million Dollar RV Build)

What happens here

The presenter walks through the chassis fabrication area, explaining that each chassis starts as a steel bottom plate on saw horses. Unlike common C-channel beams, Newell uses full I-beams with 90-degree gussets and trusses to prevent flexing. He points out specific areas within the chassis designed for water bays and sewer lines, highlighting the custom cut-outs for various components. The chassis is built to support the entire coach's weight and integrated systems, including the heavy-duty front end, which is a ZF design.

Goal: Demonstrate the robust and customized steel chassis construction.

Tools and materials

  • 90-degree Gussets — Reinforcing the chassis structure
  • A-Arms — Components of the suspension system
  • Disc Brakes — Part of the heavy-duty braking system
  • Full I-Beams — Structural support for the chassis
  • Saw Horses — Supporting the chassis during fabrication
  • Steel Bottom Plate — Foundation of the chassis
  • Trusses — Adding strength and rigidity to the chassis
  • ZF Design Front End ZF — High-performance front suspension and braking system

What they say

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i think this is the cool part because i make stuff out of metal yeah this is my zone here actually how we start you see this is going to be a mid-entry coach so every chassis is a little different depends on where you put your slides position of your slides the length of your slides you all have that many different options but the chats will be really different here because you have a mid-entry so all they really do is everything's still bottom let's go through there we start with that piece of steel right there on saw horses get it leveled out all that stuff and then we don't do a sea channel bean we do a full bean and the 90 degrees we have a little um gussets there little truss is there to help support it so that way it stops a lot of flats this right here should be the water bays that you call water compartment sewer compartment your tanks and all that right here and that's why you have this little cutout right here for your uh sewer hose you just push the front end on it you see the disc brakes right there that's some serious equipment yeah you get up in there see the air arms made in usa you can sell everything back buy steel and they'll fill all this other stuff in before they stand down and go to rustoleum like i got a big hand and that is a huge a huge caliper yeah generator area is going to be steering i see this steering shaft that's interesting he'll play his back so the front end's all zf designed yeah uh well porsche design helped us with the front end exterior design of it but zf helped us with the front end suspension rear suspension and we also have an active terrible tag action

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