What follows is the process of making an Allegro Breeze (or Phaeton, Open Road, Bus or Zephyr!)
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| All incoming lumber is hand sorted, machined and prepped for the custom cabinets. |
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| Here the boards are glued together to make the doors and tables in the coach. (You can see the frames at the center of the pic.) |
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| Very few processes are automated: the cabinetry is made by hand. |
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| Cabinet frames: the ergonomist in me couldn't help but wonder how his neck feels! |
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| Assembly (with a bit of a breeze from a really large fan!) |
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| Carpet |
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| A kitchen assembly ready to go into a coach |
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| Nice job on the drawer joints! |
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| The table has a dust collection system. |
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| I think his dust collector isn't working: notice the dust on the fan and the wall behind him! |
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| They certainly have a lot of inventory sitting around... |
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| So what is the plural of chassis anyway? |
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| A Breeze chassis (we love our little coach!) |
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| That's under the bed! |
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| Our Breeze has engine envy (I don't know which coach gets this engine.) |
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| Wires, hoses, and lots of metal for a base. |
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| They have a big paint facility in Mississippi, these guys head down the road naked and come back dressed. |
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| Rust proofing |
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| On tour with our guide, safety glasses and headphones. |
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| One of the few automated processes: an NC machine cuts the styrofoam insulation to spec. |
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| Hoses and wiring harnesses |
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| We upgraded our driver's seat. |
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| Cranes lower the floor in place |
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| Workers scramble to pull hoses, flex pipe, and wires through the floor. |
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| More carpet |
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| Cabinets go in before the walls go up. |
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| The frame goes in |
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| The cap and windshield are ready. I wondered if ours got jarred a bit? The windshield is only glued to the cap, not the frame! |
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| The roof |
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| A slide is put in place |
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| PUSH! |
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| Getting ready for the kitchen slide. |
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| Ready for a slide and a nose |
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| Very surprised to see the front cap being put in place with a forklift. |
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| Checking the emergency exit |
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| There are 2 miles of wire in our Breeze |
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| Pulling wire |
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| Prepping the wire harness |
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| Big hands for such a small job |
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| Lots of chewing tobacco (guess it's a water fountain issue!) |
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| Final checks |
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| One of the originals from the 1970's. Bob Tiffin had a vision and the Allegro line has come a long way since the original design. |
