How a Willow RV is Born

WillowRV

How a Willow RV is born

Part I

It all starts with the chassis

With a combined experience of 50 years, Willow have design their chassis in house and is manufactured by Rollcraft in Melbourne Victoria.

The suspensions are manufactured by AL-KO International in Melbourne Victoria.
These suspensions have been designed and tested for Australian conditions.

The chassis has four locations for water tanks, these are purposed to enable the moving of the two 95 L water tanks into various positions to distribute the load balance of the van to suit the customers option choices.

Willow RV

The floor is a one piece composite floor 33mm thick. Construction is 6mm commercial ply top and bottom filled with high density foam supported by a polyurethane structure. The floor final shape is precision machined to ensure the squareness of the caravan body.

Willow RV
The chassis is now prepared to receive the floor. Adhesive is applied on all the chassis members to form a secure bond between the chassis and the floor.
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Now it's time for the furniture

The furniture has been designed for ease of manufacture and also furniture panels interlock into each other for the following reasons:
Strength of the furniture
Only the correct panels can be used the correct in their appropriate places.
Avoid the use of tape measures and subsequent mistakes.

All cut outs are cut out in the furniture during machining process for the following reasons:
No need for production personnel to cut into the furniture with hand tools.
All wiring corridors are allowed for
All cut outs for equipment are in their precise locations and the correct sizes.

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Once the furniture to floor process has been completed the electricians and plumbers can now commence feeding the wiring and piping through the furniture

Willow RV
Willow RV

Once the wiring and the plumbing have been installed the splash backs are installed in to cut outs provided.

Willow RV
Willow RV
Willow RV

The van is now ready to receive the walls.
A sealant is applied around the entire perimeter where the walls meet the floor, this has two functions:
Forms a bond between the wall and the floor
Forms a water barrier

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The wall is then lifted into position.
Ensuring that it locates in the provisions in the floor (wall cannot be incorrectly positioned once fitted into its locators)

The wall is then located to the furniture that slots into the walls.

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The walls are mechanically fixed by screwing through the sides of the wall and up through the floor.

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The furniture is then screwed up to the walls.

Where ever the furniture meets up with the wall the is a corresponding polyurethane rail inside the wall that will allow a solid anchor.

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The one piece composite roof is now lifted onto the van.The roof is mechanically fixed to the van body.The insulation of the walls and roof, confirming that the Willow RV vans are truly insulated.
Roof overlap onto the walls, these walls and roofs are hail resistant and the roof is strong enough to walk on.

Willow RV
Willow RV
Willow RV