Inside the Zone RV Factory: Gen 2 Production Line | Australian Made Off Road Caravans

Join Adrian Toft, the CEO of Zone RV, as he takes us on a tour of the production line of our Gen 2 full-size caravans (the 21ft Sojourn and 19ft Peregrine).
During the walk-through, you will get a chance to learn how our vans are built, get insights on the floor from our bay leaders, and see the cutting-edge technology and construction methods that we use to build these premium off-road caravans.
You will also get to see how we incorporate components from some of Australia's most trusted brands such as Redarc, Cruisemaster, and Webasto, into our builds.
We hope you enjoy this Zone RV factory tour and gain more insight into how we make our premium off-road caravans, proudly made in Australia.
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WEBSITE: www.zonerv.com.au
INSTAGRAM: / zonerv.caravans
FACEBOOK: / zone.rvcaravans
ZONE RV, in a ZONE of its own!

[@DavidOastler]

So amazing is the battery charging system being updated for 2024.

[@ZoneRV]

Thanks David, yes some cutting edge Redarc tech will be standard in all models starting sometime early 2024 👍🏼

[@donr62]

Impressive but I do wonder about accessibility to all the systems for maintenance and rectification work years down the track. I assume wiring and plumbing can be accessed?

[@ZoneRV]

Hey Don, yes there are many access panels throughout the van to allow access to any important plumbing, wiring & systems.

[@donr62]

@@ZoneRVnever in doubt 😊

[@mrandmrsmeier8685]

Tofty this was brilliant. So good seeing the builds and the attention to detail that goes into each and every Zone. We were on the edge of our seats seeing the build numbers 🤩 lol Super excited seeing the ZSP builds getting closer to 292 and can not wait for our hand over day 🙏🏻🙏🏻💯💯 We know we have 💯 chosen an amazing concept and company to build our future full time live in van

[@ZoneRV]

Thanks Mark & Christine. It won't be long until your van hits the production line! Again appreciate you guys choosing our product and know you will love it 😀

[@richardcharlton8259]

The best caravan on the market with out a doubt forget the rest ZONE is definitely the best

[@ZoneRV]

Thanks for the high praise Richard! We too are very proud of our product 😁

[@marklaurendet1861]

Not into caravaning myself but worth a watch to see how it all comes together

[@ZoneRV]

Glad we could provide some insight into the business 😀

[@neillucas4342]

Nice vid Tofty, Love to see the inner workings of the Zone factory and so pleased we can be a part of this great Australian business. Looking forward to Handover of EXP-032 and a couple of restful days at Hangar O in the New Year. Thank you

[@ZoneRV]

Thanks Neil, glad you enjoyed. We look forward to seeing you soon 😎

[@Sawadventures67]

Awesome setup Tofty congrats on your success with zone it great to see and Aussie company doing so well cheers thanks for sharing merry Christmas 🎄 🍻👍🇦🇺

[@ZoneRV]

Thanks guys & wishing you all the best for the festive season 😊

[@bhk776]

Picked our ZPP214 “ZODA” up last Thursday 7th Dec, service has been next level and the attention to detail is the best I’ve seen. Looking forward to getting out and using it for what it was built for. Thank you to all the team at Zone RV, you nailed the brief. I have very much enjoyed this clip, seeing how it comes together.

[@ZoneRV]

Thank you so much for getting in the Zone and we are very pleased to hear you've been enjoying the luxury our caravans afford! Safe travels ZPP214 😁

[@Zumaray]

Good video and great insight into how your caravans are put together. Makes me want to consider one. Just got to get passed the fact that if you ever have any damaged to the sides, roof or floor, it worries me how long and how hard it would be to repair?!

[@ZoneRV]

Thanks for watching! Its actually very easy to repair, any fibreglass repairer can make it look brand new if it gets dented or punctured. Check out our owners page facebook.com/groups/706937541134081 and search "fibreglass repair" for some pretty impressive examples 😊

[@double-oseven5725]

Much appreciated...keep up the great work boys, I can see me buying the dual axel expedition soon!!

[@ZoneRV]

Thanks Rob! Would be great to have you in for a look!

[@paulcallan5540]

We love the sojourn. Is there a possibility of a van being built with cafe table and recliners.

[@ZoneRV]

Hi Paul, sorry but the recliners are not something that we offer.

[@tonywu683]

On the last bit of the video, there were 2 diesel tanks. I thought the heater and water heater used the same diesel tank?

[@ZoneRV]

Hey Tony, the 2 tanks are the seperate diesel hot water and diesel space heaters. Reason being the space heater is an optional extra and diesel hot water is standard 👍

[@tonywu683]

@@ZoneRV I have also ordered a March 2024 sojourn. I got the impression that the diesel tanks were combined as 1 during the sales process.

[@barrabandit]

Great insight into the build process Adrian 👌

[@ZoneRV]

Glad you liked it!

[@tofiking3944]

Very interesting video on the advanced construction techniques in a really high-quality caravan but I think that you are a bit loose with labelling everything as a composite. The battery box seems to be a fibreglass moulding and the internal wall structures look like a type of PVC foam board. I can see that the floor/walls/roof are true composite panels though. I understand it's marketing and that it sounds better, but it is a bit misleading.

[@ZoneRV]

Thanks for the comment and hope you enjoyed the video 😀 'Composite' just means its made up of a few different materials, not strictly fibreglass/foam. Hope that helps!

[@anthonywills2403]

Thanks Adrian for a great tour through the factory mate.

[@ZoneRV]

Glad you enjoyed it Anthony !

[@cameronmartin931]

And how do you ever repair that water system once the rear wall is bonded on?

[@ZoneRV]

Hi Cameron, there are access hatches scattered throughout the internal of the van for any areas that require servicing 😊

[@cameronmartin931]

@@ZoneRV Thanks for the reply, all too often designers never seem to think of this.

[@TheTripleDubya]

Nearly two months in and we’re very impressed with our van. It just makes Van life so much easier.

[@ZoneRV]

Thanks Wayde! Simplifying our systems just means more time enjoying that awesome lifestyle, great to hear its making a difference :)

[@FatPa]

No doubt these vans are up there in the top few and we have followed Zone owners thinking one day this might be us. Whilst the composite interlocking system, chassis and build quality seem great I was a little disappointed in the way the plumbing was run, just looked messy and please tell me the electrical fittings on the water solenoids in the same shot aren’t the standard crimp on types? Not a criticism of a top product, just hoping the small attention to detail areas haven’t slipped

[@ZoneRV]

Thanks for your comment! Please keep in mind that the caravan you are seeing is still in the building stage.

[@robsstuff9250]

Great video guys, well done. Got a real appreciation of the quality of work you do.

[@ZoneRV]

Much appreciated Rob! Thanks for the kind words.

[@steeldragon5867]

Do you have to have diesel water heater and composting toilet, could be a deal breaker for us, looking at the 19 footer

[@ZoneRV]

Yes, they are a standard inclusion. Have you used either? Once you do you will never go back to gas HW or a chemical toilet!

[@Tophet1]

Is it easy and is it strong ?

[@ZoneRV]

Extremely! Its the ideal material being lightweight, strong and well insulating!

[@BrinkleyRV]

Nice job!

[@ZoneRV]

Thank you! Cheers!