First Zone Expedition Hardtop unleashed

Queensland's Zone RV unveiled a new hard-top version of its innovative Expedition hybrid off-road composite caravan at the 2025 Queensland Caravan & Camping Supershow.

Priced from $179,500, the new Expedition Hardtop couple's hybrid has a starting weight of 2550kg, or around 50kg lighter than the Poptop, while it's $10,000 more expensive than the original, award-winning pop-top model.

The new Hardtop has the same 5.25m body length and 2.05m external width as the Expedition Poptop, but at 3.16m tall rides 500mm higher than the Poptop when towing. The Hardtop's internal height is expected to be 2053mm (same as the Poptop's), although final figures have not been confirmed.

Zone RV founder Dave Biggar said key differences from Zone's full-size off-road caravans include the narrower and more 4WD-track-friendly 2.5m width and an emphasis on outdoor living, while he said the composite body construction of the Expedition Hardtop is very similar to that used in the marine and aerospace industries.

Externally, the Expedition Hardtop features a large kitchen and entertainment recess which includes an induction cooktop, sink and storage compartments, alongside other hatches with a 75L fridge, microwave and slide-out bbq.

As well as a gas bottle locker, DO-35 coupling, recovery tracks, LED work light and an electric jack, the area around the spray-on rubber-protected front nosecone also gets some new storage bins for holding firewood and other outside items.

Also new is a full UV water filtration unit located within the extra-large offside storage locker, while off-grid power is supplied by a chassis-mounted 800Ah lithium battery pack with a 3000W inverter and 1080W rooftop solar.

The Expedition Hardtop rides on Cruisemaster ATX airbag suspension, with black 17in Method wheels complemented by a new flare kit, plus there's a new entry door with a Crimsafe security screen.

The Hardtop's somewhat cosy interior is largely based on the tandem-axle Expedition Poptop's, but with some subtle differences including a redesigned lounge and new overhead cupboards.

The 17ft interior length allows for a north-south queen bed up front, with the narrow lounge bench seating and adjustable Lagun table freeing up some internal floorspace. There's also another 175L fridge, with internal access via a cupboard to the outside kitchen.

While there are some more internal cupboards in the new Hardtop, most storage capacity remains in the large external lockers located on both sides of the 'van.

The re-designed rear ensuite gets a composting toilet, wall-mounted washing machine and a full-size shower cubicle, while other standard features include a Redarc Redvision monitor, Webasto diesel hot water and space heater and rooftop air conditioner, 32in TV, WiTi anti-theft unit, powered awning, reversing camera and a GPS odometer.

Water is stored in 300L (fresh) and 100L (grey) chassis-mounted tanks.

With the introduction of the pricier new Hardtop variant – aimed at buyers who want to more efficiently cool or heat their caravan when running the diesel heater or air-conditioner off-grid in very hot or cold temperatures – Zone says production of the Expedition at its Sunshine Coast factory will ramp up to five vans a week.

The 10-year-old Queensland RV builder, which started off with DIY flat-pack kits, is now taking orders for the Expedition Hardtop, with first deliveries expected in August 2025.