When you should upgrade an older caravan

Ten or 15 years ago, a couple of solar panels, an AGM battery and leaf-spring suspension were enough. But today, many caravanners want to be equipped to venture further and get to more rugged locations.

There's also the appeal of taking more creature comforts like coffee machines or even running air conditioners off-grid.

Technology advancements have naturally flowed into new 'van builds, but we're increasingly seeing it become available in the retrofit market.

A lot of this new tech can be pricey, but replacing your old 'van with a new one can often end up even more expensive. So when does it make sense to upgrade what you have, or get something completely new?

The main upgrade areas when it comes to older caravans are running gear and power.

Running gear is the major systems working to keep you safe while you're travelling down the road, and include things like suspension, axles, brakes, wheels, tyre, ESC (emergency stability control) and ABS (anti-lock braking).

Power upgrades cover items like lithium batteries, solar panels, inverters, DC-DC chargers, battery monitoring and the wiring that ties it together.

Unfortunately, caravans can sometimes deteriorate without you knowing it. The last thing you want to do is chuck a lot of money at upgrades and then discover later you have structural integrity problems.

If you're seriously considering upgrades, it's worth having your 'van professionally checked for major issues such as water leaks, signs of existing moisture, timber rot and panel corrosion or delamination. You should also have the chassis checked for signs of corrosion or cracking.

If you're just contemplating power upgrades, then you should check the status of your running gear too. We're talking broken springs, worn shocks and/or bushes, for example.

Another big issue is weights. The reality is that most upgrades are going to add weight, not reduce it. The extra weight could become too much for your tow rig.

With the caravan, you will also need to consider the ATM and axle load rating. For the tow vehicle, you need to consider tow rating, towball download, axle load rating, GVM and GCM.

At the basic end, an older 'van may benefit from new shock absorbers, bushes, springs, shackles, bearings, brake pads or tyres. We're talking here about swapping out like-for-like wear and tear parts needed just to stay roadworthy and safe; something any decent RV repair centre should be able to do.

A genuine upgrade starts with swapping out components such as shocks and springs for higher-performance alternatives, just like many 4WD ute or wagon owners do. Costs are likely to be under $5000.

For example, Cruisemaster recently introduced its Red Stag program to improve things like 'van ride control as well as reliability.

You could also consider completely replacing or adding a new system, with specialists like the Cruisemaster Towing Performance Centre able to inspect the 'van, assess options and install the right system. The other big name in caravan running gear, AL-KO, has a similar service centre in Melbourne for major upgrades.

A classic example is to remove a leaf spring suspension system and replace it with a trailing arm suspension, with the objective of improving corrugated road performance and/or load carrying capacity. This could start at $10,000... and easily escalate!

It typically involves removing the old suspension and cutting existing mounting points off the chassis. New mounting points then need to be welded in, taking into account variables such as wheel track, ride height and wheel travel.

If the upgrade includes air bags, ancillary items like compressors, air tanks and a control panel are often added for adjustable ride height and campsite levelling.

New suspension will include new axles, hubs and brakes, so running new brake lines is likely. Often, the new brakes will still be traditional drum variety, but it may be possible to upgrade to more powerful hydraulic disc brakes.

Either way, improved braking performance can be expected. New hubs may mean new wheels and tyres too, so you may need to budget for that too.

ESC is tied in with braking. Explained simply, ESC applies the caravan brakes to dampen caravan sway.

Basic drum brake ESC systems apply the brakes on both sides of the caravan in a sway event. This is a popular standalone upgrade as it's relatively easy and inexpensive (low thousands) to have fitted.

More advanced asymmetric ESC systems can break the left or right side independently to pull the 'van into a straight line, and some systems vary brake force depending on how severe the sway is.

ABS and integrated sway control go even further by using wheel-speed sensors and modulators to help prevent wheel lock-up.

These more advanced systems can also be retrofitted, but it's often more complex and expensive. ESC systems for hydraulic disc brakes are more limited, and asymmetric left/right control is not as straightforward when hydraulic lines are plumbed together.

More sophisticated ESC installs could start at around the $5000 mark.

You should also be aware that some modifications require engineering certification for the compliance plate to be updated, which adds further cost and complexity.

Improved off-grid power is the other big reason owners consider upgrading an older caravan.

Rising demand has inspired companies such as Sydney-based Signature Off Road Campers & Caravans to provide a dedicated service, SCT Off Grid RV, to custom-design and install off-grid power systems in existing 'vans.

The most basic upgrade is to switch from AGM batteries to lithium for more usable power and a lighter weight. 200Ahr to 400Ahr would be a decent upgrade for many users, and this will start in the low to mid thousands.

But the real motivation is to deliver more power, which means an inverter to power 240V appliances is on the shopping list. If you're taking more power out then you're going to need to put more power in. This means more solar panels, a DC to DC charger and some form of controller to integrate the power and show you what is happening.

If you stick with a 12V system, retrofitting is quite viable and makes an older 'van feel much more modern. This could start at around $5000.

At the top end are fully integrated 48V power systems that manage solar, DC-DC charging, mains charging, inverter output and connected loads through one central system. These can run 5kWh, 10kWh or larger lithium banks and move into the tens of thousands once batteries, installation and wiring are included. They are impressive but not always retrofit-friendly.

Upgrading an existing caravan makes the most sense when you're happy with most things about it.

That usually means the layout works, the build quality is good, and you've checked that the 'van doesn’t have any nasty hidden surprises. You will also need spare capacity in the 'van and tow vehicle to add extra weight.

It can also make sense if you know exactly what you want. A new 'van might have an impressive spec sheet, but not the battery brand, suspension type, tyre choice or electrical set-up you would have chosen. A carefully upgraded older 'van can suit its owner better than a new 'van built to hit a showroom price.

There is also the familiarity argument. You already know where your current 'van works, where it annoys you and what you would change. A new caravan can also introduce new unknowns.

To state the obvious, do not pour money into a caravan with fundamental issues.

Be careful with resale. A well-executed upgrade using known brands may make a 'van easier to sell, but you rarely get every dollar back. Buyers like upgrades, but they do not usually pay full replacement cost for them.

As a rough rule, once you're thinking about spending more than 50% of the market value of an older 'van, stop and do the hard comparison. What will it be worth after the upgrades? What would a newer 'van cost? And would the upgraded old 'van still have compromises you're trying to ignore?

Some jobs suit a handy owner. Portable solar, battery monitoring, replacing worn components like-for-like, or fitting some 12V accessories may be within reach if you know what you are doing.

But running gear and major electrical upgrades are different. Suspension, brakes, wheels, tyres, and 240V inverter integration all have safety and legal consequences. A bad drawer latch is annoying. Poorly installed brakes or a bad wiring job is something else entirely.

Before spending up big, be clear on four things...

If the answer is yes, upgrades can be a smart way to get a better touring 'van without starting again. If the answer is no, it may be time to move on.

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