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  1. #1
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    Default Off-road caravan build

    Iíve just started with the building of my off-road caravan. Will post pictures as I progress for those interested. Trailer now at galvanizing. Chassis made from 100 x 50 tubing and frame from 38x38 tubing.
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  3. #2
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    Default Re: Off-road caravan build

    Will follow your progress

  4. #3
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    Default Re: Off-road caravan build

    Being from Cape Town, does anyone know where I can get hold of caravan pop roof mechanisms as in picture Click image for larger version. 

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  5. #4
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    Default Re: Off-road caravan build

    Have you calculated the final weight?

    100x50 soundd like quite a heavy frame
    Was that just the main part of the frame or internals aswell
    If its 100x50x3 its almost 7kg per/m
    38x38x2.5 is 2.83kg/m

    Weight adds up quickly
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  6. #5
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    Default Re: Off-road caravan build

    Quote Originally Posted by Disa View Post
    Being from Cape Town, does anyone know where I can get hold of caravan pop roof mechanisms as in picture Click image for larger version. 

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    I am not familiar with caravan dealership names, but any dealership will have them, or can order it for you. I used the Explorer roof mechanisms when I made my caravan a pop-up roof.
    I might be a FOOL, but I am an OLD fool - from unknown.

  7. #6
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    Default Re: Off-road caravan build

    Disa sterkte met jou projek ek sal vordering dop hou

  8. #7
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    Default Re: Off-road caravan build

    Thanks for your replies. Will follow up and let you know what and where I found my parts.

    wall panel inserts will be refrigerator composite panels. 40mm thick.

    At this moment I am looking at a weight (empty) of around 750 - 800kg.

    I will visit the weigh bridge once back from galvanizing and assembled..... will keep you posted.
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  10. #8
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    Default Re: Off-road caravan build

    Quote Originally Posted by Disa View Post
    Being from Cape Town, does anyone know where I can get hold of caravan pop roof mechanisms as in picture Click image for larger version. 

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    Try Tygerberg caravaans
    Brackenfell Blvd & Hillcrest Rd, Vredekloof, Cape Town, 7560
    https://goo.gl/maps/1y7dXKxnj9wzNmA39


    lesuireland caravaans 11 Robert Sobukwe Rd, Unclear, Cape Town, 7530
    https://goo.gl/maps/NyansCwFgM5Y2qzn8

  11. #9
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    Default Re: Off-road caravan build

    Okay. So today Iíve received my trailer back from Galvanizing.
    So far as to weight, the steelwork came in at 320kg. Next couple of days will require some cleaning and starting to fit panels..... more posts coming

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  13. #10
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    Default Re: Off-road caravan build

    Quote Originally Posted by Disa View Post
    Okay. So today Iíve received my trailer back from Galvanizing. So far as to weight, the steelwork came in at 320kg. Next couple of days will require some cleaning and starting to fit panels..... more posts coming Click image for larger version. 

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    Gaan groot Disa

  14. #11
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    Default Re: Off-road caravan build

    Sjoe, wat n issue om die raam skoon te kry... I used the Sikaflex 11 FC. In the past Iíve used the 221 but canít seem to find it here in my part of the world.
    in progress with the profile strips being installed. Getting there, slowly but surely Click image for larger version. 

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  16. #12
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    Default Re: Off-road caravan build

    Cape Town is on fire.....
    lets hope the south easter calms down.

    Iíve finished with the profile strips . All installed. Managed to get a couple of panels installed.

    First time to cut these panels, used a skill-saw with an aluminum 60 tooth blade. It gets blunt quickly though

    Some pics added Click image for larger version. 

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  18. #13
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    Default Re: Off-road caravan build

    A few more panels installed

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  20. #14
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    Default Re: Off-road caravan build

    A few goodies I got for the caravan. Little switch panel, this caravan will sleep 4 people, so I get 4 LED 12v reading lights and 4 USB charging points together with this I made 4 pockets from plywood as a cubbyhole for each person. LED taillights not sure yet if I will install them vertical or horizontally..... little fuse box snd a 12v light fir the pop roof.

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  22. #15
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    Default Re: Off-road caravan build

    As I am no expert and this might be a stupid question... I had leaf springs that I used rated at 1150kg... is this rating max load per spring or max load of a set (2).

    my axle is a braking axle from Burquip at 1800kg...
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  23. #16
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    Default Re: Off-road caravan build

    Are you using steel strip as profile strips or or aluminium

    I take it the sheets are aluminium

    Nice build looking really good
    Where did you buy your electrical goodies from
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  24. #17
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    Default Re: Off-road caravan build

    Quote Originally Posted by whosthejman View Post
    Are you using steel strip as profile strips or or aluminium

    I take it the sheets are aluminium

    Nice build looking really good
    Where did you buy your electrical goodies from

    The panels are chroma-deck refer panels. I know itís heavier than Aluminum panels but also half the cost...

    The profiles are also same material as panels. The profiles are glued with sikaflex and screwed to galvanized frame. Panel inserts are then glued and riveted together. On the inside I will use aluminum and pvc profiles dependent on if cosmetic or structurally needed.

    I had a friend working is the US buy these items off ebay for me. Only the LED square light I bought at Gelmar.
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  25. #18
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    Default Re: Off-road caravan build

    Managed to out a few more panels in. Tomorrow I hope to get the floor panels installed. I have installed 6mm plywood first and painted it with stone chip on the bottom before i glued and screwed it down. The idea behind this is for stones and grit to rather damage the ply wood than destroying the refer panels. This plywood will require maintenance after trips with more painting etc, but rather that than damaging the refer panels. So as you have heard I am also putting these panel on the floor and will then cover it with a vinyl wood looking like floor cover.

    Click image for larger version. 

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  27. #19
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    Default Re: Off-road caravan build

    90% of the floor done today. Roof has been assembled and first cross wall for kitchen has been installed. Tail lights also installed.

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  29. #20
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    Default Re: Off-road caravan build

    Quote Originally Posted by Disa View Post
    Managed to out a few more panels in. Tomorrow I hope to get the floor panels installed. I have installed 6mm plywood first and painted it with stone chip on the bottom before i glued and screwed it down. The idea behind this is for stones and grit to rather damage the ply wood than destroying the refer panels. This plywood will require maintenance after trips with more painting etc, but rather that than damaging the refer panels. So as you have heard I am also putting these panel on the floor and will then cover it with a vinyl wood looking like floor cover.

    Click image for larger version. 

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    why not consider polyurethane (like in bakkie rear) then maintenance would be way less/almost none.

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