Construction

The base chassis are carefully selected for their reliability and suitability to the task. We use Mercedes, MAN and Volvo chassis' predominantly. A sub-frame is fitted to the chassis, in house, to create a stable structure for mounting the body to and also to construct a garage area and frames for the large lower lockers.

 
motorhome base vehicle
Mercedes base vehicle
motorhome chassis
Chassis with additional sub-frame


The vehicle walls have an insulating core of 50mm high density Styrofoam manufactured to a tolerance of +/-0.2mm for an exceptionally smooth finish. This is then sandwiched between sheets of 2mm GRP. The joints are then sealed with a Fibre Glass angle piece to ensure total impermeability. This provides thermal insulation which, incredibly, equates to a 2 foot thick cavity brick. We do not use metal framework in our walls as it compromises their thermal integrity and reduces the effectiveness of the insulation.

 
motorhome floor
Floor thickness
motorhome roof
Attaching roof to body

The floor is a massive 75mm thick, offering unparalleled insulation and stability. It is made up of a sandwich of one 25mm and one 30mm sheet of high density styrofoam, one sheet of specially selected 15mm plywood and an inner and outer skin of 2.5mm and 1.5mm GRP respectively to produce a perfectly water-proof seal.

Apertures are cut out of the panels for windows, doors and slide-outs. The body is assembled in-house and is then prepared for painting prior to being fitted to the chassis.

 
motorhome body
Body shell

Joining the shell and chassis