From the all-important chassis to the tiniest screws, every aspect of the manufacturing process is tightly monitored with rigorous quality control taking place at each stage. Our goal is to provide you with a custom-built caravan that will keep you happy on your travels around the country while making for some life-long memories. 

Design

As soon as an order is received from our nationwide network of dealers, the in-house design team at Lotus Caravans drafts a building plan for the van, based on the client’s requested dimensions, features and components. This plan is sent off for final client approval.

Undercarriage

Top quality water tanks and braking mechanisms are affixed to the chassis and floor while the installation of robust underbody armour guarantees ultimate protection. Minimal openings in the floor allow for plumbing access to ensure maximum strength is maintained and dust ingress is minimised.

Electricals

With the exterior walls and frames in place, technicians complete all the electrical wiring in several stages, completed by the installation of both 12V and 240V components, such as the economical 12V LED light fittings, air conditioning, road lights and thermal wall and roof insulation.

Plumbing

Expert plumbers prepare the pipework and, as each element is ready, connect the:

·      Gas fittings

·      Hot water service

·      Sinks

·      Showers

·      Toilets and taps

Chassis

Lotus Caravans has built a great relationship with G&S Chassis, Australia’s leading chassis builder, to construct each frame based on the design in the building plan. It is delivered to the factory and the caravan begins to take shape.

Flooring

The only other constructional element made off-site is the structural grade one-piece floor, which is built to specification and prepared for assembly, including its single-piece hardwearing vinyl covering.

Walls and Roofs

The walls and roof are constructed in the Lotus Caravans factory before being fitted onto a lip on the chassis, taking pressure off connecting bolts. The caravan’s internal framing works in conjunction with the walls, chassis and roof to provide sturdiness and stability in even the toughest conditions.

Exteriors

With the construction almost complete, doors and windows are fitted and sealed against the elements before the final design details are applied to the distinctive grey aluminium cladding along with composite panelling and checker plate armour.

Interiors

All fixtures and furnishings are individually built on-site by skilled cabinetmakers and craftsmen. Every bench, cupboard, berth and bulkhead is inserted by hand to fit perfectly.

Quality Inspections

Throughout every stage of construction, each van is assembled according to stringent quality standards, overseen by a quality supervisor. Upon completion, the caravan is subject to rigorous structural and safety testing before being weighed and compliance checked. After a thorough clean and polish, inside and out, a member of the management team conducts a final detailed inspection before the caravan can leave the factory. Our vans also receive the seal of approval from RVMAP, the official Accreditation Key of the caravan industry.

See our manufacturing process up close by booking a factory tour.