Jayco Expanda 2005 Review

By Ron and Viv Moon

The Expanda range of vans from Jayco is so-called because of its ability to expand to a much bigger unit when set up. The range includes two 12ft models and two 16ft versions, all of which are pop-tops, while the 18-footer is a fully-fledged caravan unit.

The small units have only one foldout bed and both the 16- and 18-footers have a foldout bed at each end of the van, while the large van has a slide-out lounge, taking the term ‘Expanda’ to the limit!

We took a 16ft Expanda all around Oz, but prior to this long-term test we checked out one of the 18-footers.

Our 16ft unit was an alloy clad frame version, but all of the Expanda range now features what Jayco calls its ‘Tough Frame’ exterior wall construction. The 18-footer on which we did the one-day test came with this new body construction style, which includes a 25 x 25mm tubular alloy frame with four layers of material.

These layers include fibreglass, ply and polyester foam, while the outer fibreglass layer is finished with a high-gloss gelcoat skin, some 1.5 times thicker than the previous aluminium skin finish.

The final stage of the manufacturing process is the vacuum bonding of the frame for added strength and quality; this style of construction, by Jayco’s admission, provides an almost dent-resistant 100% insulated frame.

The body top and rooftop frames are aluminium while the roof is a solid-domed one-piece fibreglass unit. Such a construction method ensures good strength as well as keeping the centre of gravity for the whole unit low.

Prior to our testing, this unit had been run on the test tracks at the Anglesea proving ground in Victoria and had been given a sustained flogging on the ripple strips to see how this new construction method would survive extreme outback corrugations. When we got it, the unit was still as tight as a drum.

The whole thing rides on Jayco’s Millennium Design chassis with unique PSC cross members, which are used to support the 13mm floor and are reportedly more resistant to bending and compression than normal standard box section steel.

The 18ft Expanda included the optional Outback Pack: a solid beam axle backed up by a seven-leaf suspension setup with rebound damper springs to improve the shock absorption of the spring. In addition there are hydraulic shock absorbers while the tyre rim size increased from 14 to 15 inches.

These bigger rims wore 235/75R15 Dunlop Super Gripper rubber. The Outback Pack also adds bigger, stronger 150 x 50mm main chassis members, a 125 x 50mm A-frame, improved electric brakes and an obvious aluminium checkerplate finish to the sides and rear.

The two configurations of 16ft pop-top available are similar, one having an in-built toilet/shower combo which dictates a slightly different layout of sink and stove and a little less storage space.

The 16-footer we have on test doesn’t have the shower/toilet, but it comes with so much cupboard and storage space we are a little nonplussed as to what to do with it all.

We are carrying a mobile office with us, which includes two laptop computers and a host of ancillary equipment that takes up four of the overhead cupboards, so that is saying something.

Three of the storage areas were accessible from outside; two were a little hampered by their outside doors, but had full access from the inside. The large storage area on the offside of the van had too small a door for real handy use, while storage on the nearside only allowed part-access due to the support arms of the Carefree awning, which meant it could only be accessed if the awning was set up.

The interior features also include a large stainless steel sink, mains and hand-pump-fed water to said sink, four-burner stove and grill unit – one burner is a very handy 240V element, meaning you don’t need to use gas when on caravan park supplied power.

A 12V light and rangehood complete the cooking area, although a microwave is now standard fare. A Dometic RM2350 three-way fridge looks after food and drink while 12V lighting throughout the van means there is ample illumination.

A 240V AC to 12V DC converter and battery charger, along with a heavy-duty battery looked after power supply in the van.

What we really liked about this 16ft unit was the amount of space we had when it was set up. With the beds folded out from each end and occupying none of the floor space that beds do in a normal van, we found there was ample room to live and work comfortably.

The large island and lounge seats around the offset swivel table accommodated four people for the first month, then just Viv and me after that – we lived, ate and worked in comfort without getting under each other’s feet!

Setting up took just a couple of minutes. Access to the interior was possible even without the roof lifted and we made many lunch stops with the roof down. Lifting the roof easily into place involves four clips and a slight push of the canterlevers inside, at each end of the roof.

The beds – both very good-sized doubles – took a little longer to deploy. A couple of screw-down locks need to be undone and then the wall-cum-base of the bed is dropped into position, supported by strong stainless steel cables.

From the inside of the van a support frame that extends the canvas and the bed, which is folded slightly (with bedding in place), is allowed to fold out and the whole operation is complete. It was again remarkably easy and quick but still, elderly couples may find lifting the drop-down bed back into the travel mode position a little too strenuous.

Only when we were staying for more than an overnight stop did we bother deploying the Carefree awning – not that it was any great trouble to do so, it just wasn’t required in such situations. These awnings are self-supporting but in windy WA they really need a couple of guy ropes to ensure they don’t lift off!

Another big plus for Jayco’s Expanda is the amount of ventilation it has to offer. Each bed end has three large insect-screened windows; these are located at each end of the van to ensure a good flow of air throughout.

That was important, especially as we chose to do without the optional air-conditioning and the weather sat between 36 and 42 degrees for the whole two weeks while we were at Exmouth!

We then experienced rain – some of the best rain WA has had in years – and we travelled and camped in that for four days.

Once again the Expanda came through with flying colours. However, such a bed setup means that you need to protect the bed with a blue plastic tarp or similar so the wet canvas roof doesn’t saturate it. Campertrailer users will know all about this precaution, but really it’s a small price to pay for the unit’s convenience.

On the road the van tows very well. Weighing in at just over 1400kg empty the van is probably nudging 1800kg to two tonnes when full of water (our unit and the optional second water tank), supplies and the like, but its travelling height is no higher than our Patrol is, with roof rack on, so wind resistance is negligible.

Certainly the Patrol knew it was behind, especially on the hills, but on open roads we generally cruised at 90-100km/h.

Our excursions off the tarmac at this point have been limited to just a few hundred kilometres but the van and its suspension have handled it well. You can’t expect to get into places that a smaller, lighter offroad camper trailer can, but then you don’t get the luxuries plus working and living space that you do in an Expanda, either.

We did head down a few dirt roads, some of which were quite corrugated, as well as a few soft sandy station tracks looking for a remote, quiet camping spot beside the sea. The Jayco took everything in its stride!

Jayco’s 16ft Expanda van is like living in a 22- or 24-footer but with all the advantages of towing a much smaller unit. After living in it on the road for a couple of months now, we can only agree. It works extremely well and with fuel prices as they are, it makes a lot of sense to tow something smaller.

For more information on the Expanda van or any other Jayco caravans and products, see the complete range at your nearest Jayco dealer check the web at www.jayco.com.au or write to PO Box 636, Dandenong, Vic. To find your closest Jayco dealer contact (03) 9791 6599.

We liked:
• The amount of living space when set up
• Compact towing size
• Cupboard space
• Outback pack
• Ventilation

We would have liked:
• Better access to storage areas from outside
• Battery and charger to be positioned less obtrusively in storage box
• A lightweight fly over the bed sections to keep moisture off the canvas.

Jayco Expanda Series
Model: 6.49-1 18.57-1
Body length: 16ft 1in 18ft 8in
Interior body length: 15ft 6in 16ft 10in
Travel body length: 20ft 7in 23ft 7in
Extended length: 23ft 7in 26ft 4in
Travel height: 7ft 3in 8ft 7in
Interior height: 6ft 11in 6ft 4in
Width: 7ft 6in 7ft 8in
Front bed size: 1830 x 1470mm 1830 x 1370mm
Rear bed size: 1830 x 1370mm 1830 x 1195mm
Ball weight: approx 95kg 180kg
Tare weight: approx 1210kg 1760kg
Price: On application On application