VIN 15 - Factory Build Log

[turbopilot]

Ultimately I'm doing this for me, but for everyone interested, so once I know what you are all interested in, I can deep dive a little more in those areas.

As I said in a previous post, this is a new to the world machine. About the only thing in common with previous towable RV's are the owner skills associated with towing. And even towing is different because of aerodynamics and TrekDrive. So the early owners really have to learn the machine. These threads and posts go a long way to helping each other learn while at the same time leaving valuable information for other future owners.

It is not easy being an early adopter, but it is very interesting to learn and appreciate the new technology.

 

[JK_AZ]

Found your video a couple of days ago and loved it. Thank you for taking the time to record this process. And thank you to Lightship RV for allowing a client to do this. As a potential client it's a great marketing tool to cement Lightship as my choice since this type of video series let's me see the process, people and gets me invested with the company. Looking forward to the series.

 

[josephpRV]

Found your video a couple of days ago and loved it. Thank you for taking the time to record this process. And thank you to Lightship RV for allowing a client to do this. As a potential client it's a great marketing tool to cement Lightship as my choice since this type of video series let's me see the process, people and gets me invested with the company. Looking forward to the series.

Agreed. +1 thanks to the Lightship team for allowing the access. As a startup their processes are far from mature but they’re evolving quickly, and it’s great seeing the evolution week to week.

This Wednesday I’ll be deep diving Station 2 where they install the actuators for the canopy cycling up and down. I’m intensely interested in this as a process and from a mechanical and functional standpoint.

Any questions you want me to ask the team just let me know!

 

[josephpRV]

Post # 4

VIN 15 Build Path Tracker | March 25, 2026

✓ Station 0 – Parts Staging
✓ Station 1 – Underbody
>> Station 2 – Tub Frame and Actuator Calibration (factory walkthrough this week)
□ Station 3 – Interior Assembly
□ Station 4 – Canopy
□ Station 5 – Marriage
□ Station 6 – Validation & Testing
□ Station 7 – Delivery

Legend:

✓ = VIN 15 current progress | >> = current post documentation | □ = Upcoming posts/videos

Quick summary

VIN 15 is still wrapping up in Station 1 with Station 2 – Tub Frame and Actuator Calibration up next.

Station 2 looks simple on paper. Install the bonded floor and four canopy actuators. In practice, it’s one of the more precision-dependent steps so far. Going into my purchase, my two biggest personal question marks were:

1. TrekDrive efficacy for EV tow range, and
2. Canopy actuator robustness (especially after miles of washboard dirt roads)

After a tow demonstration, I became comfortable with TrekDrive. Today’s visit increased my confidence in the Canopy actuators. Based on what I saw in person, the actuator assemblies appear significantly more robust than I expected from the spec sheets alone.

What happened this week

As always, thanks to Hayley, Ruby, Ben, Zach, and the production team for letting me wander the floor asking more questions than planned. Despite best endeavors the visits are never 30 minutes. I show up with a running list of “how does this actually hold up over time?” questions, and to their credit they keep taking the time to walk through them right on the floor with hardware, testing, and the people behind the decisions. Ben’s actuator deep dive this week was a perfect example of that level of access.

VIN 15 remains in Station 1, but the platform is starting to look substantially more complete than last week. Since my previous visit they’ve installed:

• Front axle
• Both HV batteries
• HV harnessing
• Coolant pumps
• BMU and onboard charger
• Tongue-box electrical center
• HVAC condenser and heat exchanger

There’s significantly more structural tubing than I expected. Zach mentioned this last week, but it really has to be seen in person to appreciate the scale. The photos and video give a better sense of it.

Station 2 – Tub Frame + Actuator alignment

Hayley mentioned last week that Station 2 looks simple but takes time. After seeing it, that tracks. Two major steps happen here:

1. The bonded structural floor goes in
2. The four canopy actuators are installed and aligned

The floor install itself is straightforward. The actuator alignment is not. Ben Robbins walked me through the validation work they do on the actuator assemblies. For anyone interested in a deeper cut on the actuators, the companion video has it all.

For those who can’t watch, here were my key takeaways:

• The actuator and mounting structure are (of course) extremely rigid
• The assemblies become even stiffer once the tub walls are added and bonded
• In travel mode, the canopy load sits on bumper stops, not directly on the actuators
• The customer experience with an actuator cycle is about 2 minutes up and 2 minutes down
• There is a manual fallback if ever needed

I tried unsuccessfully – and with permission - to shake the actuator assembly while it was mounted. It didn’t move. That went a long way to answering my durability concerns, particularly after a dirt washboard-road type scenario pretty quickly.

What I learned from the team
I asked Hayley about customer support and how they’re thinking about long-term service scaling. Right now there are two support paths:

1. Remote support - Phone diagnostics and software resolution where possible.
2. Mobile technician support - Used when hands-on intervention is required.

Mobile service obviously doesn’t scale forever, so I asked when that changes. Her answer was simple: when the data indicates it should. She also walked through how quickly field learnings are already being pushed back into active production builds, with OTA functionality on the roadmap to support that longer term.

Fun observations from the factory

• VIN 8 - Yellowbird was heading out for road testing while I was there. The rear light bars look even better in motion than in photos.
• For those familiar with manufacturing environments, I noticed a clear step change in inventory organization and placement alongside builds.
• Floor snapshot 03/25:
  • 1 unit road testing
  • 2 units in finishing (one staged for marriage)
  • 3 units active across Stations 1–3
  • 1 canopy staged and 1 looking close to ready

Photos and Video

Attached are updated Station 1 photos for VIN 15. This week’s video includes actuator alignment discussion with Ben as well as VIN 15 progress with Zach and Customer Support ethos with Hayley.



Questions for next week

1. How are sub-floor wiring and plumbing installs validated before closure?
2. What durability standards are required from utility vendors?
3. How complex is the interior systems install once Station 3 begins?

If you have any questions you'd like me to ask, post below. Note, if they involve future stations, I'll hold them in reserve until that station.

Next Station in the VIN 15 Build Sequence

Station 3 – Interior Assembly which includes installation of interior systems including utilities, cabinetry, drawers, appliances, and internal electrical/plumbing systems.