Ep. 273: How They Build an RV | KZ Durango fifth wheel construction

Have you ever wondered how your RV was made? We certainly did, so we visited the KZ Recreational Vehicles Durango plant in Shipshewana, Indiana to find out for ourselves, and we're bringing you along on this Grand Adventure. We toured and filmed the factory during production hours with the company's GM, documenting the building of a Durango from start to finish. We'll even sit down with KZ's president for a chat.
Filmed: August 29-31, 2022
CHAPTERS
0:00 Intro
0:56 All about KZ RV
2:35 Frame prep
4:06 Floor deck
5:12 Linoleum flooring
5:41 Moving units down the line
6:05 Side walls
8:33 Interior walls and cabinets
9:45 The roof
13:05 Slide-outs
14:18 Front cap
14:58 Pressure testing
15:37 Decals and windows
16:00 The finished product
19:34 KZ RV President Aram Koltookian
23:30 Wrap-up
FOR MORE INFORMATION
* KZ RV kz-rv.com
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Welcome to Grand Adventure, a KZbin channel that focuses on RV-centric outdoor activities including not only of course camping, but also mountain biking, hiking, kayaking, skiing and more, always filmed in stunning 4K.
We're based in Salt Lake City, Utah during the winter months, and invite you to come along as we travel all around the U.S. My wife Patricia and I, and dog Zoe are avid boondockers, so while you'll occasionally find us in RV parks or even dry campgrounds, we're usually camped in some of the most remote and beautiful spots that you could ever pull a travel trailer into. We've now transitioned from "long-timing" for six months a year, to living and traveling in our RV full-time.
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#RV #camping #fifthwheel #kzrv @KZRV1972 #kzdurango #howitsmade #GrandAdventure #camper #RVlife #RVliving #rvlifestyle

[@jawski68]

I am actually amazed, that they actually make these trailers like a brick/mortar home, actually making it feel like a real home. Actually pretty impressive, they actually do this kind of work.

[@jordancook1668]

If only you got paid by the “actually”

[@randyhuggins288]

🤣🤣‼️

[@slickwilly6944]

They're "actually" giant pieces of shit. Stapled and glued together.

[@Ivansgarage]

"brick/mortar home" is built on a concrete slab, these look like a Lippert frame, NOT GOOD

[@Mike-pk5gc]

I couldn't stop hearing this guy say "actually". It's endless with this KZ guy! 🙂

[@cardwelljc]

Great video. I own a 2022 Venom 3313tk. I have had very little issues wrong with it. With all the frame issues I see on KZbin, the name KZ is not involved with any of it. Watching this video gives me comfort of the quality of my Venom. Next week, im taking it to the dealer to do a roof inspection which I will do once a year just to make sure all is good. The dealer will inspect and repair anything they see that could cause damage in the future for $200 and I think that is money well spent. Easy money for the dealer and I get assurance lol.

[@GrandAdventure]

That sounds like a win-win scenario. Thank you very much for your kind comments and for watching!

[@derikwright3383]

Everyone working hard when the VP shows up. Would prefer quality over quantity myself.

[@GrandAdventure]

At 10 units per day, KZ is not a high volume manufacturer.

[@peterkettelkamp7162]

I find the construction process very interesting. What was reinforced in your video is how fast the employees have to work. I understand that employees in the RV manufacturing industry are paid per RV completed. This compensation method does not emphasize quality manufacturing, which we all know is a real issue today. Keep up the great videos.

[@GrandAdventure]

Good observations Peter, and thank you!

[@Grizz_Bane44]

Bought our first 5th wheel this year and its a KZ and we absolutely love it. 291BHT. Super cool to see how they are made. I trust this company even more. Great video yall. Thanks for putting this out there.

[@GrandAdventure]

Our pleasure. Congrats on your new purchase, we hope that you are as happy with yours as we have been with ours, and thank you very much for watching.

[@EricWright2001]

I would have liked to hear and see what type of insulation they use in the production of these RV's. Great to see the process but like on their brochures where they talk about the materials used I would like to see that also in this video. I am really leaning towards buying a KZ Durango Half Ton so this was informative. Thanks for putting it out,.

[@GrandAdventure]

Our pleasure, Eric, and thank you for the feedback!

[@JandAReview1]

We have been KZ owners for over two years now. This was a great video showing how they are made. KZ is the first manufacturer we’ve seen to put up outside walls up before they put in cabinets,Most build inside-out. Hopefully one day we will make it to the factory!

[@GrandAdventure]

We hope that you're as happy with yours as we are with ours. Thanks so much for watching!

[@jesib7526]

I had a Durango and I really liked it.

[@mowguy1]

The word of the day. Actually is Actually

[@johncooper5777]

Very informative video. Very well done . 😊

[@GrandAdventure]

Thank you John!

[@thetraveltrailerguy]

Nice video Marc, so far this is the most informative RV factory tour video I've seen put out in the KZbin world. Thank you so much

[@GrandAdventure]

Thank YOU Michael! It took some arm twisting to be able to film during production hours, but we felt that was too important and made too much of a difference.

[@ruahinesrider]

It's great to see they take pride in their work & do a very good job especially being filmed these days where quality is slack with other brands.Other brands probably wouldn't want you to film 🎥 them Incase you see them taking short cuts.

[@GrandAdventure]

Thanks for watching! We were wholly impressed with KZ's operation, especially after we've been wholly impressed with our first two years of ownership. The biggest impediment to filming during production hours was the fact that the Amish don't allow themselves to be filmed; however, we made the request and they readily agreed after consulting with the Durango plant manager, who is Amish himself. That told us a lot even beforehand, and it sounds as if you drew the same conclusion.

[@ruahinesrider]

@@GrandAdventure Great to see their standards are high.10% bonus if they pass a certain high standard gives workers incentive to do a better job maybe all manufacturers should do this due to the drop in quality control & rough building across the industry.2 yr hitch to bumper warranty too.I have been researching the industry & brands & who uses Azdale & who uses Luan & what slide mechanisms they use & KZ Durango is the best & is the one I would get.

[@leighmcqueeney9848]

Fascinating. Looking at buying a 5th wheel in 12 months time. Durango is top of the list. Cheers Marc. The 2 Tasmanians at Potawatomi Campground Illinois.

[@GrandAdventure]

Happy shopping Leigh, and safe travels!

[@daviscrt]

Looks Like the KZ family is doing quality work. So cool to actually seeing a rig being build. Thanks Don

[@GrandAdventure]

Thanks for watching Don!

[@gina50gina]

It was really interesting to see how KZ makes their RVs. The people who build them are very motivated!

[@GrandAdventure]

We appreciate you watching as always, Suzane!

[@benm2116]

Yeah the Methamphetamines do wonders!

[@Elizabeth-rq1vi]

We’re smitten by the Durango Gold 356RLQ. We’re planning on going full time in about 18mos. for a few years. Doing North America…especially Canada.

[@GrandAdventure]

Those Golds are nice units. We're in no hurry to change rigs as we finally got ours tweaked just the way we want it, but when the time comes we're planning to look closely at the Durango Golds.

[@Captndarty]

Really great tour and was very entertaining. I will say, if automotive manufactures had the same quality control and dirty assembly hall they’d be out of business within a year. All RV’s are built like crap. I’ve had plenty. And yes the customer service was excellent but you shouldn’t ever really need to speak with them. I mean a certain RV GM went on record saying hinges on doors are designed for 40 something uses. They’re disposable and expect a customer to use them a week or so year and get rid of them after a couple years. They are not designed for full-time living, which requires you to treat it like a paper house. Every RV on the lot I go into has crumbs from the particleboard and wire splice of shavings in the corners on the floors. Every RV that I have owned has had a significant recall, impacting the safely and or use. That being said there’s no alternative and if you want to play you have to pay and that mean tolerating a subpar quality unit. Thank you for what you do and the knowledge and entertainment your channel brings.

[@Setinmywaysalways]

This could be one of the answers to social Housing

[@alanjones9884]

Thank you for the tour of the KZ plant.

[@GrandAdventure]

It was truly our pleasure to make this one for all of you, Alan. Thank you as always for watching!

[@bradsmith1441]

You are very professional in your whole presentation! Thank you

[@GrandAdventure]

Thank YOU Brad!

[@gardcorelegend]

Amazing work by the KZ crew putting those RV's together.

[@GrandAdventure]

They definitely work their tails off.

[@kgadigital6234]

This is actually a drinking game.

[@GrandAdventure]

😆

[@scenicdriveways6708]

Interesting video Marc. Well done. JT

[@seymourscagnetti1413]

The one guy is missing his arm. Probably blown up at the irack war (maybe). A lot of our guys got blown up by terrorist time bombs under their jeeps. Always great to see people overcome adversity.

[@brianmyers466]

Awesome video! Thank you

[@GrandAdventure]

Thank you Brian, and thanks for watching!

[@gorrdd]

Thanks Marc. I found it a little overwhelming to follow as things were happening so fast. But that is to be expected based upon a 25 minute presentation of a day to three day build process. The process covers several units under construction simultaneously with crews working on several different units in stages. It's hard to determine how long the process takes. Actually and obviously aside... I liked the interior materials and fixtures choices and of course the Durango floorplan is fabulous. Personally, I'm not crazy about the step up into the bathroom and bedroom required of a fifthwheel. I prefer the flat footprint of a travel trailer. But it was fun to see how they do it. Their plant is very thorough and efficient. You have to be to build a reputation and survive. Nice to see that the Covid buggers didn't destroy this plant. Gord

[@GrandAdventure]

We walked away extremely impressed by the plant's efficiency, Gord. You're right about the speed, but that's also largely a KZbin phenomenon as people have short attention spans these days. Each segment focused on one station along the way from raw frame to finished product. That way we could logically follow the build process from start to finish.

[@momskelton5794]

Thank you, this was an interesting tour of KZ!

[@GrandAdventure]

Happy to hear that you enjoyed it! Thank you very much for watching.

[@timothyjohnson8036]

Nice video Marc.. It was very interesting to watch.,.. thanks again 👍👍👍

[@GrandAdventure]

Thank you Timothy!

[@bobcruikshank2010]

Wow! Those assembly workers really hustle! Great video!

[@GrandAdventure]

They sure do, Bob. Thank you!

[@joedolan7669]

Great video. Can’t wait to purchase my first Durango!

[@GrandAdventure]

Thank you Joe! Here's hoping that you find exactly what you're looking for.

[@MegaRenegade800]

Great Video Marc, I have always been impressed by the quality on these Rig's

[@GrandAdventure]

Thanks as always for watching, Eugene!

[@Hanr3]

Excellent Tour. Thanks. I learned a few things. I've been in Quality for 30+ years in various manufacturing environments. Really like teh Bonus tied to Quality. I could see that saving a ton of money in returns. Plus building KZ as a Quality Brand in the Industry. Really nice to give a bonus to the workers. Always nice to get a little extra for doing a good job. I also like the pressure checks mid-build.

[@GrandAdventure]

You're most welcome, and thanks so much both for watching and sharing your observations and experience in QC!

[@akgobears]

LOL, somebody got to teach this guy another word besides actually....If i had a buck for every time he said that word in this video i could have retired 10 yrs earlier....Just funning (actually) LOL !!!....Different kind of video, interested in where we will see you next week...Hope you enjoyed Shipshewana ....How did you like them Amish buggies with the lights and turn signals on em LOL...Another thing i remember from there was a place called Yoders (Amish store) and a whole lot of old time bicycles..The flee market is kewl too, i know you went and stayed there too....Travel safe, be well...

[@GrandAdventure]

Actually... 😉 next week's episode will be our more typical travel content from Shipshewana and Elkhart. And yes, we were treated to a buggy ride by some truly wonderful folks.

[@paulshannon4576]

But actually it’s actually what he’s actually doing. You know like, like. 🤣

[@derikwright3383]

I made that a dinking game. Took a shot every time he said that and did not make it to the end. Massive hangover 😅

[@akgobears]

@@derikwright3383 LOL

[@mountainskyaerialphotograp3921]

We own a KZ 285R 5th wheel. The fit and finish is high quality. It's a 2013 model.

[@GrandAdventure]

We're happy to hear that you're as happy with yours as we are with ours. Thanks for watching!

[@johnrodgers356]

The video was awesome. KZ build quality is outstanding. One thing I found awesome was the wood dowel placed in the bottom and top of the aluminum frame all the way around. Makes for a solid structure. With azdel sidewalls, that's even more exciting. I'm going to be purchasing 2023 Durango half ton D283RLT to full time in solo. Thanks

[@GrandAdventure]

Our rig is a 2020 D283RLT, John. You're going to love it!

[@johnrodgers356]

@@GrandAdventure thank you for the reply. Yes I'm glad you love yours and I will as well.

[@DownsizingMakesCents]

Hey Marc, love all the detail shown in this video on the production process. I would love to see how our rig was built, what is under the floor? Sounds like KZ is doing a good job with quality control, which we know is a big problem in the RV industry. Thanks for showing this insider view of an RV manufacturer. Larry

[@enarandyr9122]

Hopefully they improved QC at KZ INC. I own a 2020 Durango gold and had multiple major issues that had to be resolved by myself. KZ wouldn’t do anything but refer me to my dealer that was backlogged 4 months. I was going to sue them but the costs of the lawyers fees were just a bit steep. Luckily I have worked in the RV business back in the 80’s so I had the skills and knowledge to do the repairs myself. Sad thing is they wouldn’t even ship the required parts to me free of charge. Against company policy was the excuse. I video documented all the issues. One day I post them all. Looking to upgrade to a VanLeigh soon.

[@GrandAdventure]

Sorry to hear that you've had that experience, Randy. In all honesty our experience has been markedly different from yours.

[@rik8809]

Amazon is building a distribution plant in nearby Elkhart. They plan on hiring around 1000 workers. With the unemployment rate in the area already running under 1%, someone’s going to have trouble finding workers.

[@GrandAdventure]

Sure sounds like they will, Rik.

[@marshmallow1488]

Only if Amazon pays at least $50/hour.

[@laughingram7287]

Very cool to see this plant and how they put together the Durango trailers. It probably gave you a good piece of mind knowing that you own a Durango trailer. Very good mic and your interviewing has much improved! It was all very professional. Thanks for putting this video together. Ram 👍🏼👍🏽

[@GrandAdventure]

Thank you David! The mic was the biggest challenge, for it is incredibly loud inside that factory. It was darned near impossible to isolate our audio from the background noise.

[@conniewaite1371]

There is a guy on utube ,incredible tiny homes,who is teaching the amish how to build tiny homes.awesome show

[@billdennis2993]

Thx for an informative and entertaining video Mark. Been a KZ fan for years always wanted a Escalade Sportster BITD but DW, wallet and TV limitations made it a 38' New Vision Sportster that We enjoyed for many years of use including USFS roads getting to primative campsites high in the Sierras. I never got it any where I couldn't manuver out of and the Youngs welding frame, Dexter axles GY "G" rsted tires , 5th Airborne W sidewinder airride pinbox kept it from getting shook to pieces. Our present 40' 3axle KS Fuzion hasn't proven to be as durable as our KZ was unfortunately, boon docking access limitations crimped our style. Happy Camping and stay healthy GA.

[@GrandAdventure]

Thank you Bill, and same to you! Those are both very large rigs from our perspective, but good on you for getting them both out there and enjoying them.

[@DanyRivard]

A luxery house on wheels !!

[@GrandAdventure]

Pretty much, Dany. We love calling it our home.

[@vickiwhite725]

Love it! Why tho waste valuable space for a fireplace in the bedroom??

[@GrandAdventure]

Believe me, there are times in the winter that I wish we had one in there. However, the fireplace leaves an enormous amount of space behind it that's usually wasted. That's one thing that impresses me about the Alliance builds, the higher end Paradigm models put the fireplace in a drawer to access all the space behind for storage.

[@kurtschulmeyer1041]

Did they tell you average time per unit start to finish? I love the 1 piece roof, less likely to leak with over lapping sides. Great video.

[@GrandAdventure]

Thank you Kurt! I know that they produce 10 units per day, but don't know how long they're in the production line.

[@TomSpurlock]

Nice tour Marc. I like most all of the construction methods, amenities, appliances, and testing that goes on. The only disappointment was the membrane roof. I don't believe the lifetime warranty, given the nature of how membrane will weather and eventually fail after 10 to 15yrs. Ask me how I know. It really needs to be a fiberglass roof IMHO. But overall, nice construction.

[@GrandAdventure]

Appreciate your feedback as always Tom, and thanks for watching!

[@SevenBears1]

Only change I made to my KZ was removing all decals . Only repairs have been loose screws and plastic ribbon .

[@GrandAdventure]

We've had a few minor issues, but nearly all have been related to parts supplied by third-party manufacturers.

[@mikedoran4763]

I once worked with a Mark Guido at an sign shop in SW Florida back in the 1980s. We were about the same age and when not working we'd were fish'n buddies. I do realize there are many who share the Guido name, but wonder if this Mark Guido ever lived in Port Charlotte, Fl.?

[@RexDeaver]

Was that particle board on the roof?

[@CharlesinGA]

OMG, he actually said actually more times than you said Coeur d'Alene, actually!

[@GrandAdventure]

😁

[@allued9393]

Can’t wait to see your Oregon Inlet nags head video….

[@GrandAdventure]

Were you a neighbor?

[@allued9393]

@@GrandAdventure yep….

[@allued9393]

@@GrandAdventure enjoy your content

[@GrandAdventure]

@@allued9393 thank you! Wish we had gotten the chance to chat.

[@dougkaledo6018]

Hi just wondering if KZ does a PDI similar to Grand Design on each unit or if they have the dealership do it there on site?

[@GrandAdventure]

Ours was done at the dealership, Doug.

[@hjkkmtukk3990]

How the ground looks like absolute mess the workers have so much pressure running around. No wonder all of the units have issues. Really sadly to see that.

[@buddyray6792]

Every RV Factory tour I've ever seen - the employees are literally RUNNING everywhere, all the time. I know the Amish value hard work, but If I had to work at that pace for 8 hours a day I'd make so many mistakes. I guess that's why in my RV (full disclosure, not an KZ) I found a very nice set of channel lock pliers behind the furnace, a screwdriver behind the power panel and none of the slats on the decorative vent in front of the Furnace were stapled in. The staples were there, they just all missed the wood on the other side.

[@GrandAdventure]

Sadly Buddy, what you describe doesn't surprise me in the least.

[@swansodi]

I have a small airstream, thinking about getting a B or B+ van. Not much interest in a large travel trailer

[@GrandAdventure]

Certainly to each his/her own according to his/her needs, Dian.

[@Ivansgarage]

Are they using a Lippert frame? that's a No No.... to many frame failures driving down these rough roads...

[@GrandAdventure]

Their frames are supplied by Lippert, but as full-timers and avid boondockers we've brought it down some pretty rough Forest Service and BLM roads over our nearly 3 years of ownership. No issues have been identified yet, confirmed via a full frame and suspension inspection this spring.

[@norrismckee1619]

I wood like to see a connet

[@GrandAdventure]

Perhaps next time we're there. We're seeing many, many Connects in the wild this summer.

[@ophirpass]

How high is the upper deck interior ceiling height?

[@GrandAdventure]

It varies by model. Some like ours are a mid-profile, while other models are a full profile.

[@alfredabbey6162]

Do they make a winterized version?

[@Elizabeth-rq1vi]

Yes, he didn’t mention it but the Durango Gold is designed (so they say) for full time use.

[@GrandAdventure]

Even our Half-Ton is a true 4-season model, but the heavier Gold units do get beefed up insulation. We winter in Utah in ours and get by without any skirting.

[@tjjm1907]

First blush I am amazed at the trash on the floor and the hoses and equipment scattered hither and there. Sad and unsafe.

[@rd4660]

Now I know when they crash, they fly into little itty bitty pieces!

[@JMc1125]

How many times did he actually say actually??

[@GrandAdventure]

😆

[@gorrdd]

Wow, Marc. I'm surprised you're airing this now while your still traveling and not saving it for this winter. Gord

[@GrandAdventure]

Too good to not share now. ;)

[@gorrdd]

@@GrandAdventure Yeah... Elkhart is the main place for much of the RV production out there. I'll be interested to see what you share this evening. Gord

[@GrandAdventure]

@@gorrdd next week's episode will focus on Elkhart and Shipshewana.

[@gorrdd]

@@GrandAdventure Cool... I gather that Elkhart was traditionally a vacationer's destination, back before RV's were a huge industry. Would that be correct, Marc? Don't know much about the area and haven't done the research. Gord

[@leemaisel7157]

I'd like to see the manufacturers actually focus on build quality. I and many others are horrified at the poor quality of modern RV's.

[@patrickhastings6421]

I think I’m going to retire the word actually from my vocabulary!

[@jefflancaster9221]

Do not take a shot every time he says actually you will die.

[@GrandAdventure]

😆

[@derikwright3383]

Glad they don’t make aircraft 😮

[@hjkkmtukk3990]

I even would feel bad buying one of this after seeing how hard the workers need to push it around. Really how bad this will be when the camera is not running I don't want to know. Better I give my money to a brand that treats there worker's well and they can build quality. I will put my money to work for a better product and working ethics and pay gladly 30% more

[@uowebfoot]

10 per day? How can that be good quality? Notice how all the workers are running around and doing everything as fast as they can. Their incentive is to put out as many units as they can. It's not about quality it's about quantity.

[@GrandAdventure]

Assembly line. By contrast, the majors are pumping out 100+ per day.

[@dramc-ov3cp]

Looks very much like an old auto assembly plant from before the advent of modern manufacturing. Front cap insulation not secured, floating fore and aft in the cap? If so, then not very effective. The process appears to be rushed, not conducive to best quality work. The auto industry learned their lesson, time for the RV industry to learn theirs. Steady as she goes and follow the process gives best results.

[@derikwright3383]

Would not buy any camper with Samsung appliances