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Build Process

You may be wondering how off road caravans are built – scroll down to see our build process at Grand City Caravans!

We prioritise Australian built & high quality componentry where possible and provide transparency into our component suppliers. We are proudly 100% Australian owned & made. By buying a Grand City, you support Australian jobs, businesses & families across multiple industries. We also welcome any potential customers to book a factory tour to see the quality control and craftsmanship that goes into building a Grand City Caravan.

Let’s start with one of the important parts of the caravan, the foundation beneath it; the chassis. Your caravan starts its life at FP Chassis, one of Australia’s highest quality chassis companies. Sourcing steel from Australian mills AusTube Mills & Orrcon Salisbury Mill, FP Chassis will custom build our chassis to your specific requirements. So whatever customisation you can imagine, whether you’re looking for a GripSport Bike Rack on the A frame to take your bikes, or a Black Jack Trailer Jack so you don’t have to manually wind your jockey wheel, through FP Chassis, we can design your caravan, the way you want it.

FP Chassis offer suspension from several high quality Australian suspension manufacturers, such as Simplicity, Tuff Ride, Alpha & Cruisemaster, allowing you the flexibility to decide which suspension you’d like on your custom built luxury off road caravan.

So whether you’re looking for the Cruisemaster ATX Level 4 Self Levelling Airbag Suspension or wanting to increase your payload on single axle caravans to 3,000kg with the 3T Tuff Ride Extreme Coil Suspension, we can tailor the caravan to your suspension requirements.

We use Cruisemaster XT Freestyle Coil Suspension as standard on our Tracker, Nomad & Explorer.

The floor is CNC cut 12mm film face ply with a hardwood core that is coated with a high density overlay resin finish, which is both glued and screwed directly to the chassis. This is followed by the laying of the floor, which is a ultra durable European made vinyl with multiple colour options available.

Our caravan furniture is designed & built in house, using state of the art 3D modelling technology and CNC machinery. Utilising modern European style frameless cabinetry, & double laminated gloss ply with interlocking furniture that is screwed together (not stapled), our furniture is built tough to last several years of caravanning.

By using 3D modelling, this allows us to see the position of the furniture against the walls, floor and roof. By visualising the position, we are able to reinforce areas along furniture partitions for increased strength when screwing through the floor, wall and roof; utilising a strong box style construction method, and avoiding stapling into furniture.

The caravan is built from the inside out, and the furniture is first placed onto the caravan floor and screwed from underneath before the walls are put up and screwed again.

Once the furniture, walls and roof is screwed and ready to go, our electrician gets started on wiring and our plumber gets started on the rough in. Once this is complete, the caravan is insulated and then clad with aluminium composite panel and aluminium checker plate using high quality adhesives. After this, the fit out is completed with the installation of windows, access doors, and any other accessories. The final step is an interior and exterior detail clean followed by a rigorous quality control checklist of more than 100 items to make sure any issues can be detected and rectified early.