Construction Process

The starting point of the process was the production of the caravan floor. This was produced as a two tier laminated sandwich construction that would accommodate the two bolt-on extension units. This was then fastened to a standard Al-ko caravan chassis to complete the base unit.

Because of the complex nature of the exterior, unlike current production models, it was decided to build the body shell and then tailor the interior fittings accordingly. The two side elevations consisting of flat aluminium bonded panels and shaped GRP sections were constructed first.

Next a lattice work timber frame was erected to support the large hemispherical aluminium roof span.

Bespoke acrylic front and side windows were subsequently installed to complete the basic body shell construction.

Cargo S was then transported on its first journey to a specialist spray painting company to receive its distinctive blue and silver colour scheme. Upon its return a specially made gas bottle locker box and corner steady units were fitted to the structure

The removable slide out bedroom section featuring double fixed bunks was constructed and added to the main assembly.

The rear deck unit complete with folding rear door section and awning canopy was then fixed into position.

Prior to the installation of the ceiling the electrical wiring looms for the interior lighting and caravan road lights were run.

The caravan furniture was constructed into modular units similar those found in current production models. Then using traditional wood working skills the panels were scribed (shaped) and fixed to the interior of the hemispherical body shell.

The interior appliances and fixtures were sourced primarily from our existing supplier base selecting items that completed the contemporary design. Once these were installed finishing and dressing operations were carried out to complete the production process.

In total Cargo S took in excess of 1000 man hours to produce. Because of the limited time scale available the finished product is a model, rather a fully operational caravan, that remains as true to the original conceptual designs as possible.

Company Director Nigel Mattfield, who oversaw the build process, commented, “We’ve been delighted to be involved in this project, as it has really allowed us to push the boundaries in terms of caravan prototyping and construction techniques”.

“Of particular interest has been the opportunity to work with different shapes and materials in the build process” he continued.

Thanks go to...

Bailey would like to thank the following companies for their assistance in the production of Cargo S

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