A Visit to the SylvanSport Factory
In the latest issue of Wildsam magazine, we reviewed the new Vast travel trailer from SylvanSport. For that review, we spent a few days camping in the Pisgah National Forest, not far from the company’s headquarters and factory in Brevard, North Carolina. That gave us the perfect excuse to drop by and tour the facility for ourselves. There, we had the chance to see how the Vast gets made and learn more about the RV manufacturer in general.
Photo Credit: Kraig Becker
Lightweight Towables Built for Adventure
SylvanSport was founded in 2004 with the expressed goal of helping people get outside as often as possible. To achieve that objective, the company created the Go, a lightweight, multifunctional pop-up camper that doubles as a gear hauler. The towable proved to be so popular that it earned a loyal following with customers who love its versatility and size. The Vast is a more traditional take on the travel trailer, albeit with some very clever ideas baked in.
The popularity of the Go—not to mention the impending build-up to the launch of the Vast—prompted SylvanSport to move into its current 60,000-square-foot facility in 2019. The outside of the building features a clean, modern design with the company’s logo emblazoned above the entrance to the onsite factory store. Visitors are encouraged to drop by to check out the company’s line of products, including the Go and the Vast, the Go Easy cargo trailer, the TrailLoft micro camper, and the Loft rooftop tent. The store also sells third-party camping gear and accessories to complement a variety of outdoor adventures.
Inside, the building includes an array of offices and meeting rooms, although the sprawling warehouse area garners the most attention. Unsurprisingly, this section of the facility is by far the largest, housing tall storage shelves packed with parts and construction materials, along with an open shop floor where the Go, Vast, and other trailers are manufactured. On the day of our visit, there was even a prototype of a brand-new model that SylvanSport isn’t quite ready to talk about just yet.
Photo Credit: Kraig Becker
A Guided Factory Tour
One of our tour guides was none other than SylvanSport founder and CEO Tom Dempsey. He got his start in the RV industry in the early 90s when he went to work for the pop-up camper division at Coleman. Later, he would work extensively in the kayak industry, too, but his time at Coleman has had the most influence SylvanSport.
As we wandered the factory floor, Dempsey took us inside several Vast travel trailers at various stages of completion. Along the way, he pointed out how the trailer’s wiring and plumbing are meticulously installed, improving safety and reliability. This gave us an even deeper appreciation for the vehicle, as SylvanSport’s engineers have clearly put as much thought into the little details customers won’t see as the ones they do.
That construction process involves many steps beyond just building four walls, a floor, and a ceiling. For instance, the Vast ships with 800 watts of on-board solar panels and a large bank of lithium-ion house batteries that require intricate wiring. It also has the largest double-pane acrylic windows in the RV industry, which aren’t easy to install either. The trailer’s signature Glide-Out Kitchen System is a singular feat of engineering, too, allowing the entire galley to move outside, creating space for a massive indoor shower.
“Currently, it takes us a little more than week to build a Vast trailer,” Dempsey told us during our December visit. “But as the team gets more familiar with the process, we’re shaving off time. Eventually, we’ll get it down to just a day or two.”
Photo Credit: Kraig Becker
A Vast Difference
If you’ve read our review of the Vast, you know we love the travel trailer. But seeing exactly how it is built gave us even more appreciation for the towable. Its thermal composite walls, floor, and roof give it a rugged durability unlike anything else on the market, creating a camper designed for years of use. That is even more evident when watching the SylvanSport team lovingly put each trailer together with precision and care. The result is an RV designed for four-season camping and capable of supporting just about any kind of outdoor adventure.
As impressive as the current SylvanSport facility is, Dempsey tells us the company plans to expand its operations in the near future. Part of that expansion is to meet the growing demand for the Vast, but it will also allow other projects to come to fruition. He and his team hope to reveal more details on some of those plans soon, including the aforementioned prototype model we saw during our visit.
The expansion will also help facilitate one project that has already been announced—an all-electric Class C motorhome. SylvanSport revealed plans to build the vehicle in 2021, and while not much has been heard since, it remains in active development. Dempsey hopes to share an update at a later date, telling us he sees a lot of promise in e-RVs. He is especially bullish on Class C models that offer more comfort, versatility, and space than an electric camper van.
Photo Credit: Kraig Becker
Bright Future
After spending a couple of hours at SylvanSport’s headquarters, it’s hard not to get excited about the company’s future. The Go is already very popular, and the Vast is charting new ground for the RV manufacturer. Catching a glimpse of what is in the pipeline and seeing the dedication and focus of the entire staff only fuels that excitement. Fans of the brand certainly have a lot to look forward to.
Want to check out SylvanSport’s facilities for yourself? If you happen to be in Brevard, NC, the company’s factory store is open Monday – Friday from 9:00 AM to 5:00 PM. Visitors can also request a tour of the manufacturing area as well. The company’s HQ is located at 21 Welcome Street, Brevard, NC 28712. Visit SylvanSport.com for further details.
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