CONSTRUCTION

      All body components of the chassis mounted vehicles manufactured by Dodgen Mobile Technologies are made from molded fiberglass. Molded fiberglass is one of the most complex and expensive forms of fiberglass possible. The process involves design of a mold made in the mirror image of the necessary part. The mold is made extra thick and heavily reinforced to guarantee that the mold stays plumb and true over time. The surface of the mold has a special toolinig gel coat surface to withstand use for hundreds of parts as the parts go through a catalytic cure (rapid temperature changes). Any imperfections left in a mold will transfer into each and every part made in the mold.

      Manufacture of parts in this method involves waxing the mold with a release agent, then spraying the mold with the outer colored gel coat finish. After an adequate cure time, the part is then sprayed with catalyzed resins and reinforcing fiberglass strands. The part is then allowed to cure. If additional strength is needed, the mold and part may be returned to the spray area and wood or steel inlaid parts may be added and encapsulated into the fiberglass.

      After final cure, the part is removed from the mold carefully so as to not damage either the part or the mold. The mold is then waxed and begins its cycle to build another part. The pulled part is taken and any overspray or flanges added to facilitate manufacturing are cut or ground from the part to make it match the final useable design of the vehicle.



      Dodgen Industries opened its own cabinet manufacturing facility in 1999. This division is known as Cabinet Masters. Prior to that year, all cabinets were built by outside suppliers.

      Dodgen Mobile Technologies has the ability to mix several materials and methods into the cabinets that we produce. Our standard construction consists of real furniture grade plywood (not particle board), covered in plastic laminate surfaces. The sheets are taken to a CNC router that cuts the various parts as designed in our CAD department. Cabinet faces, floors, dividing walls, and shelves are made from this plywood. Raw exposed edges are then covered with color matching PVC edge banding to hide the layers of the plywood and match the laminate color.

      Dodgen can also manufacture commercial cabinets using oak, cherry, or hickory veneer plywood in lieu of plastic laminate if the prospective buyer wants a different look. Using any of these woods, a catalyzed lacquer finish is applied to seal the wood. (At this time we are not offering stained cabinetry.)

      Countertops are made from the same laminate-covered plywood as standard, with a choice of hardwood edge banding or plastic laminate edge banding depending on the application or desired appearance. As options Dodgen can manufacture countertops made from solid surface material (similar to Corian) or from stainless steel to avoid damage or corrosion.

      Cabinet doors and drawer faces are made from an MDF core lumber wrapped with a vinyl surface to eliminate extra seams. This insures that the doors and drawer faces are durable and can withstand abuse or disinfectants for germ control. As options, Dodgen can manufacture doors and drawer faces made from hardwoods such as oak, cherry, or hickory depending on the desired look of the decor or the intended use of the vehicle.

      Cabinet doors and drawers are installed with heavy duty hardware. Doors and drawers have latches so that the doors or drawers will stay shut during travel. Drawer boxes are made with dovetail construction, and the drawers are made to withstand proportionate loads to the drawer size. Full extension heavy duty tracks are commonly used.

      Visitors to our facility typically comment on the quality of our cabinetry and how it resembles cabinetry found in an expensive home. Tours of our cabinet facility are offered to our factory visitors to see first-hand how we build-in "Quality".

          Dodgen Mobile Technologies uses several subassembly steps in the manufacture of our vehicles.

        In this step the truck chassis is brought into an area and any necessary welding is done. This can involve extending the end of the frame; installing exhaust heat shielding; or installation of cross members for the mounting of the floor. This welding is completed in an area away from other workers due to welding flash. Then the welding is undercoated with rust prohibitive and allowed to dry.

        Meanwhile in another subassembly station, the wood walls of the vehicle are built to specifications and lined with the interior wall sheathing. Next the walls are moved to the vehicle and installed, along with 3 or more unique steel roll bars that Dodgen puts into every vehicle.  Select wire harnesses, and some plumbing components are installed along with the floor covering. Insulation, moisture barrier, and the outer fiberglass skins are installed. Then the truck is set aside awaiting its turn with the Final Assembly Team.

        The second small parts subassembly station produces wire harnesses, water lines, drainage piping, preps holding tanks, tests and prepares appliances and sinks, and any other parts that make sense to do in advance. These parts are then loaded to a cart and sit awaiting their turn at either the Chassis Prep or Final assembly stages. As you would tour the Dodgen facility you would see many carts traveling and positioned at work stations to avoid needless walking!



        Dodgen operates a sewing subassembly station. Here custom cushions, draperies, and valance components are sewn to provide a kit of parts for the Final Assembly Team to install as the vehicle nears completion.

        Back in 1982 Dodgen Industries moved to the Japanese method of manufacturing known as TEAM. Dodgen developed production teams to manufacture the variety of vehicles. A team consists of four individuals who focus their work on specific assignments. But like in sports teams, those individuals must be able to cover the work of their fellow workers and aid each other in day-to-day manufacture.

       The team consists of an exterior finisher, an interior finisher, a plumber, and an electrician. If for instance a vehicle has no plumbing, then the plumber must be multi-talented and cross trained to assume other work during the manufacture of that specific model and keep the team operating efficiently and on-schedule.

       Teams are also cross trained to be able to build a variety of our products. Because it is impossible to know the mix of what models will sell at any given time, the team must be able to step up to the challenge of the models currently sold.

       With the Team method of manufacture, the vehicle never leaves the workstation. The vehicle stays in one spot and never moves from the time the team starts until it is close to 100% completion.

       Dodgen uses subassembly steps prior to the team start, and installation of options after the team completes the vehicle to speed up the process.

       The Quality Control Department performs a number of inspections to insure that the vehicle is built with the highest quality, and complete before the vehicle is presented to the new owner.

       First the vehicle is inspected from top to bottom against a list of company standards and work instructions. Any work found incomplete, or not completed to the company standards is noted on a written report and sent back to the Final Assembly Team members to complete. If it involves either fiberglass or cabinetry, a person from those divisions comes to the vehicle to rectify the issue. Dodgen believes in the philosophy "that you learn by fixing your mistakes."

       Next the vehicle is subjected to two types of leak testing. First an air pump device is installed inside and the vehicle is pressurized to test for leaks using soap bubbles. Body joints, lights, windows, doors, etc. are sprayed and tested. When it passes this test, the vehicle can then movet to the next stage of testing.

       The vehicle is tested using HyPot electrical testing on circuits. Trailer 12-volt connections are tested. The Hertz acceptable range and voltage are tested on any installed generator.

       The plumbing system is tested as well. Pressurized water lines are tested; water and holding tanks are flood tested, and lines are filled and observed for leaks. LP gas lines are tested for leaks, and the proper regulator pressure it tested. Appliances are then burned on LP gas as a test.

       Next each vehicle is road tested for about 60 miles or more. The vehicle is subjected to rough roads, cross winds, and other factors to insure that all chassis systems are performing normally. Also, noises in the cabinetry, rattles, or wind leaks are found, and noted so that they can be repaired.

       The last test before the final cleaning step is a 15 minute zero-tolerance leak test. The vehicle is subjected to pressurized water sprayed at the vehicle from every angle simultaneously. The inspector stays in the vehicle during the test and looks for drips or leaks of any type. If anything is found, it is repaired and re-tested until it passes this test.

       All testing papers are completed and checked to make sure that the buyer is getting all owner's manuals, and that the company has records for our files on the new vehicle.