Our Process

Emerald Luxury Coaches are built on the legendary Prevost X3-45 chassis and body structure. When the X-Series was launched in 1984, it was North America’s first 102-inch, wide-body coach. Since then, the X-Series has become a favorite of professional drivers for its comfortable drivability, precise and secure dynamic qualities, and superior ride characteristics. The X-Series also is renowned for its versatility, with enough overall height to provide a spacious interior, but low enough to go places where larger coaches cannot without risking damage.

The Emerald’s Prevost-manufactured features and attributes include:

    • Integral stainless steel structure for optimal passenger safety.
    • Rivet-free shell siding.
    • Stainless steel body up to the beltline.
    • Environmentally friendly Volvo D13 engine exceeds EPA emission regulations for clean air and fuel economy.
    • Independent suspension and low center of gravity for excellent drivability.
    • Ultra-smooth ride with longest wheelbase in class.
    • Prevost Electronic Stability Program for optimal control in adverse conditions.
    • Class-leading interior headroom.
    • Lowest overall height in its class, for easier access to low-clearance locations.
    • 30-inch-wide entrance door with fewer and lower steps than others in its class for easier access.
    • Abundant under floor storage and custom conversion space.

When an X3-45 shell arrives in our facility from Prevost, it is a drivable but bare-bones unit. All the power train and chassis systems are in place, tested and operational, and it also includes the slide-outs and exterior graphic design. Then our team of highly skilled technicians, craftsmen and fabricators get to work converting the shell into your fully equipped and meticulously prepared Emerald Luxury Coach.


Quality and Craftsmanship

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Emerald Delivers:

  • State-of-the art engineered design
  • Quality fabrication and construction
  • Highest grade materials, including hardwoods and tile
  • Superior fit and finish
  • Finest details and quality
  • Clean layout for ease of service

Our design and engineering team is focused on achieving perfection is everything. Every aspect of an Emerald coach, from the electronic systems to the fit and finish of our custom wood cabinetry, has been carefully engineered and selected to provide the highest level of quality.

For example, after your cabinetry is fabricated, it is pre-installed to check for perfect fit. Careful measurements are made, then the cabinetry is removed, modifications are made so the fit everywhere is tight and completely secure, and finally the finish is applied before the cabinets are re-installed. This delivers the best fit and finish quality possible, and the entire structure is stronger and free of squeaks or rattles.

All the steps in our production process are completed in-house – cabinetry, electrical, plumbing, upholstery – nothing is sub-contracted. This allows much tighter quality control for every step, with highly trained and experienced specialists for each step that make quality control easy to track.

We have invested in the latest state-of-the-art equipment to ensure that your motorhome is built with detailed precision, including computer-controlled routers and sanders. But by no means is it all machine made; fine hand craftsmanship is involved as well, giving the finished product that special feel, warmth and glow that only the human touch can achieve.

Lightweight Framing Structure

After two years of research and engineering, Emerald Coach has developed a durable, lightweight structure that frames the interior of our motorhomes – the foundation for all of the interior fixtures and systems we create and install. The need for a strong yet lightweight structure to support cabinetry, fixtures and furniture led us to benchmark best practices in not only yacht design, but also aircraft and aerospace technology – industries that face similar engineering challenges..

The resulting solution not only helps minimize mass, but also helps to distribute the coach’s weight as close to the ground as possible, which lower’s the coach’s center of gravity for improved handling and roll-resistance. In addition, after an Emerald coach’s interior structure is crafted, this sub-frame serves as an ideal vehicle for the routing and mapping of wiring, plumbing, and HVAC componentry – resulting in an overall organization and simplification not found in most RV coaches.

This solution is industry-leading within the Prevost conversion community, where every cubic inch of interior space counts, and where weight management is such a critically important factor in optimizing fuel efficiency, vehicle handling and stability.

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Prevost was founded in 1924 when cabinet-maker Eugene Prevost created his first wooden coach body in Sainte Claire, Quebec. Prevost was a master craftsman who insisted on the finest workmanship, and the company has been diligent in sustaining his legacy. Time does not change Eugene Prevost’s kind of thinking; he and Emerald CEO John Walker would have seen eye-to-eye, each one a perfectionist who would never settle for anything but the highest quality.

Today, Prevost is a wholly owned subsidiary of the Volvo Bus Corporation, and a leading manufacturer of premium touring coaches and shells for high-end motorhome and specialty conversions.

Prevost has built a well-deserved reputation for high quality and exceptional durability. Its manufacturing processes and systems are stare-of-the-art, including micro-precision assembly. A jig for “zero-tolerance assembly” maintains perfect alignment and positioning while each piece of the stainless-steel structure is welded. This ensures that the vehicle has maximum resistance to stress and

deformation, and structural integrity that provides exceptional riding comfort and performance that stands the test of time.

Prevost’s meticulous attention to quality has earned the company’s manufacturing and after-sales operations the prestigious IS0 9001:2000 certification.

Concern for the environment has led to Prevost earning ISO 14001 certification (environmental protection) for its manufacturing processes. Prevost was the first North American motorcoach manufacturer to earn these certifications.

To learn more about Prevost, please visit: motorhome.prevostcar.com.


Prevost Chassis System

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  • Integrated chassis and Prevost Beam for a remarkably strong, durable rigid structure.

  • Prevost’s independent suspension system, including precisely sized and tuned stabilizer bars on the front and drive axles.

  • ZF Servocom® power steering for exceptional directional stability and handling precision.

  • Prevost Electronic Stability Program for enhanced vehicle control and reduced risk of rollover.

  • Anti-Lock Braking System for safe stopping across a wide range of road and weather conditions.



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Volvo D-13 Engine

Volvo’s D13 engine has an impressive track record for both impeccable reliability and remarkable durability. The engine delivers impressive performance with excellent low-end torque, and has proven itself over tens of millions of miles of heavy truck applications in the world’s harshest conditions.

The D13 also meets requirements of the more stringent heavy-duty diesel EPA emissions standards for 2010 and beyond, thanks to its advanced Selective Catalytic Reduction (SCR). It reduces diesel emissions and improves air quality, while simultaneously increasing fuel efficiency. In fact, the Volvo D13 for EPA 2010 and beyond delivers the best fuel economy of any 13-liter engine available today.

Volvo’s unique vertical installation and rooftop diffuser mount also contribute to clean and efficient engine operation, because the SCR and diesel particulate filter system generate less heat in the engine compartment.

Allison® World 4000MH, 4th Generation 6-Speed Automatic Transmission

The Allison fully automatic transmission offers proven reliability and durability – and no power interruptions during shifts. This transmission provides excellent shifting performance for fast acceleration, enhanced operating flexibility, and high levels of occupant comfort. Prevost engineers work closely with Allison to offer the most efficient gear ratios adapted to each application. This transmission carries a 5-year/200,000 mile warranty.



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