Shell Construction

It takes four fiberglass shells to build the Oliver, two inner shells and two outer shells. The lower outer shell is first bolted to the aluminum frame.  Some of the electrical wiring, all the plumbing lines, and the holding tanks are placed inside and the connections are made.  Next the” inner bubble” is created by the bonding of the upper and lower inside shells. Inside the “bubble” created by these two shell are molded the seats, counters, cabinets and the recess for the floor tiles.  At this time, all appropriate holes are cut into the “bubble”, the cabinets are finished off with their lighted interiors and doors, more electrical wiring is added and connected and the “inner bubble” is lowered inside the waiting lower outer shell.  Plumbing connections are made in the kitchen and bath areas, wiring is connected to the lower areas and the upper outer shell is affixed to cap it all off.  The series of pictures illustrates the process of producing each of the shell pieces.

Travel Trailer Shell Construction
For a superior finish you have to start with a clean and polished mold. Any imperfections in the mold will show up in the gelcoat. In the picture you can see that the finish is like a mirror.
Travel Trailer Shell Construction
All the shells are constructed starting with a transportation grade gelcoat that resists chipping from road debris and rocks. A UV protectant is added to help reduce fading by the sun.
Travel Trailer Shell Construction
A skin coat of neat resin and chopped fiberglass is added and hand rolled to remove any air pockets in the shell.
Travel Trailer Shell Construction
Core mat is added to the roof and glassed in.
Travel Trailer Shell Construction
On top of the core mat, we add Nida-core, a very strong honeycomb type composite material. The air pockets in the Nida-core also serve as an additional layer of insulation. You can see where we do the same for the walls where the windows and other attachments are to be installed.
Travel Trailer Shell Construction
On the outer lower shell, the channels for the frame are hand laid with two layers of woven mat and topped with a layer of bi-directional glass cloth. This adds strength to the frame preventing it from twisting and adding stability to the whole trailer and improving the tow ability.
Travel Trailer Shell Construction
The same layering process above is used on all four shells in the areas where they will later be bonded together.
Travel Trailer Shell Construction
The shell is then extracted from the mold
Travel Trailer Shell Construction
Once cured the shells are pulled from the mold and the cycle starts over to produce another set. The pictures above show the top outer shell being pulled. You can see the location for the custom high mount Oliver light in the picture above.


CONTACT US 1-888-526-3978




Contact Info

Oliver Travel Trailers

737 Columbia Highway
Hohenwald, TN 38462
Sales Office Toll Free Phone: 1-888-526-3978
Sales Office Local Phone: 1-931-796-1178
Parts & Service: 1-866-205-2621
Mon - Fri 9:00AM - 5:00PM CST

If you are interested in viewing our manufacturing plant, tours are scheduled Monday thru Friday 10AM CST. Plant tours are available by appointment only and require 24 hour notice.

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