The Finest Caravan Construction Methods

Willow RV caravans are genuinely fully insulated. This means your caravan is better protected from weather extremes – keeping your caravan cooler under the harsh Australian sun, and warmer on those frosty winter mornings.

Immense Durability

Insultuff© one-piece floor. The floor construction is a cladded, high-density foam, 30mm thick composite which forms a barrier from rising cold and moisture.

Enduring Strength

Insultuff© composite one-piece roof and walls. The roof and walls construction have a seamless outer skin which is hail and dent resistant, offering an outstanding barrier against the elements.

Exacting Detail

The entire Willow RV caravan range is designed and manufactured in Pakenham, Victoria using state of the art technology, numerically controlled machinery and analysis software.

Reliable Chassis Design

Chassis is designed by Willow RV and manufactured by Rollcraft in Melbourne, Victoria. The chassis has four locations for water tanks, these are purposed to enable the moving of the two 95L water tanks into various positions to distribute the load balance of the van to suit your option choices.

Secure Bonding

Strong adhesive is applied on all the chassis members to form a secure bond between the chassis and the floor.

Reassuring Floor Structure

The floor is a one piece composite floor 33mm thick. Construction is 6mm commercial, ply top and bottom, filled with high density foam and supported by a polyurethane structure. The floor final shape is precision machined to ensure the squareness of the caravan body. 

Integrated Furniture Design

The furniture panels interlock with each other to deliver internal strength and durability. The furniture is prepared, lifted and secured to the floor.

Precision Joinery

Furniture is slotted into the walls to ensure that the furniture is correctly located. The furniture then becomes integral with the structure of the caravan.

Strategic Furniture Incorporated

Once the furniture to floor process has been completed, the electricians and plumbers can commence feeding the wiring and piping through the furniture.

Wiring Looms and Water Lines

After complete wiring and plumbing has been performed with the wiring being fed through the furniture, a sealant is applied around the entire perimeter where the walls meet the floor.

Handcrafted Strength

The wall (single piece 30mm thick Insultuff) is then lifted into position and located to the furniture slots in the walls. Ensuring that it locates within the provisions in the floor.

Exterior Durability

The roof (single piece of 30mm thick Insultuff) is mechanically lifted and fixed to the van body, overlapping onto the walls. The walls and roofs are hail resistant and strong enough to walk on.

Sleek Exterior Elements

The van’s front wall is fitted into position and mechanically fixed.

Exterior Fittings

Exterior appointments such as the windows are prepared and sealed when installed into the walls.

Rear Wiring

The rear wall is now prepped for the lighting, you will note that these ducts in the rears are open and the wiring is accessible from within the van.

Body Shaping and Securing

At this stage all the trailer lights are fitted as well as the beginnings of the van decals.

Roof Fastening

Roof components such as hatches, TV antenna, solar and air-conditioner etc. are installed and sealed up. Roof joins are sealed around the full perimeter.

Aluminum Exterior Sealant

To complete the sealing process, the aluminium corner mouldings are secured into place with a rubber seal, ensuring complete water tightness.

Finishing Touches

All the van decals are fitted at this stage, with final polish and internal checking.

Quality Assurance

Once the van has been completed, comprehensive testing will begin.

Caravan Weight and Registration

Every van is weighed on routinely calibrated scales to ensure legislative requirements are met and the registration process can be completed.