Zone RV tackles overweight caravan problem

New Zone RV boss Jamie Johnson has announced a pricey new lightweight option pack for its mid-range off-road models, aimed at buyers who want up to 800kg or more payload when touring around in the full size 3500kg ATM 'vans.

The $24,900 Carbon Ultralight option pack is available on Peregrine, Sojourn and Sojourn Family hardtop models and includes a shower floor, front toolbox and battery box made from carbon fibre, and lighter weight furniture including resin-infused carbon fibre benchtops.

Johnson said the new option pack allows heavy-duty off-road suspension, big off-grid battery packs and other bulky items to be fitted to the 19-21ft Zone off-grid 'vans, while keeping them down to around a 2600-2700kg Tare.

He said the carbon fibre toolbox contributes to a 50kg weight saving, with a further 10kg deducted by adding the lighter battery box. Zone is also seeking to save "three or four kilograms" by fitting a lighter wheel and tyre package on future models.

The new carbon fibre parts are supplied by One Composites, which was previously part of the Coolum-based Zone RV group but was purchased by Melbourne-based Innovative Composites after Zone went into liquidation earlier this year.

A 21ft Zone Sojourn caravan on display at the 2026 National Outdoor Living & Caravan Expo in Melbourne in July came loaded up with $59,295 worth of options, including the Carbon Ultralight pack, and was priced at $243,735 driveaway.

Also on display at the Victorian RV Sales dealer stand at the show was a new top-spec 23.3ft Zone Summit 'van priced from $278,00. The 2026 range-topper boasts a starting tare weight of 3350kg.

A Zone RV Expedition Hardtop, which was unveiled in production form at the 2025 Queensland Supershow, was also on display, priced from $192,500.

The optioned up display unit, fitted with 800Ah battery bank, Cruisemaster ATX Unleashed suspension, washing machine and leather stitched upholstery, was advertised at $214,450 drive-away.

Meanwhile, Zone RV said it recently celebrated a '50 van' production milestone at its Queensland factory, since the new owners took over around March.

Prior to its collapse, it's believed Zone built as many as 500-600 'vans a year at its Coolum Beach production facilities.

Zone's cheapest 'van currently starts at $176,500, although that could be undercut by a proposed new single-axle 3000kg ATM model in the works...

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