Flat pack toy hauler breaks cover

The Queensland manufacturer of Australia’s first do-it-yourself, flat pack caravan has sold its first toy hauler model to a quad bike enthusiast.

The slick, composite-panelled Zone RV toy hauler caravan features a rear garage with room for two quad bikes and a drop-down electric double bed, kitchenette with sink, cooktop, oven, fridge, microwave and stone benchtops, ensuite with toilet and shower, hot water system, LED lighting and 400Ah battery ‘bank’.

It boasts a 2000kg Tare and impressive 1500kg payload, although Zone RV general manager Marty Bell said he’s confident of shaving around 200kg from overall weight on subsequent models with refinements to the company’s Tufflock composite panels along with the introduction of a new lightweight, aluminium chassis (pictured).

As the custom-built, tandem axle 22ft ‘Toy Zone’ caravan was supplied ‘fully built’ from Zone RV's Coolum Beach factory, it had a top-end price tag of $51,000. However, the buyer could have elected to save some coin and go down the DIY route, for around half the up-front cost.

Bell said Zone RV, which has a background in the marine, transport, aircraft and civil composite industries, also recently delivered two, flat-pack caravan kits to West Australian buyers.

“We’re offering the service from flat pack to full build, including customisation,” he said. “We can do everything, pretty much.”

For those less confident on the tools, or with minimal garage space, Zone RV can also supply a rolling chassis with water-tight ‘empty shell’ that can be stored outside while the interior fit-out is completed.

Bell said the new business had “quite exciting” plans for 2015, with off-road versions in development including a toy hauler family van with fold-out bunks, outside shower and room for an off-road buggy.

“Our caravans are designed so that you can retro-fit or add things later, or we can design a ‘camping kit’ that can be removed if you want to use the van for something else,” he said.