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Full Product Range > Caravans > New Caravans > Bailey Alu-Tech Body Shell

Bailey Caravans              The Alu-Tech Body Shell




The First Of Its Kind

The Alu-Tech construction system is the first of its kind in the UK caravan industry and shares many similarities with the monocoque production designs currently used in the automotive industry. It incorporates a system whereby the individual body shell components all contribute to the overall strength of the structure rather than solely relying on the floor and chassis.

The Alu-Tech Construction System incorporates state of the art vehicle technology featuring an interlocking aluminium external framework that clamps the body panels together to produce a shell that is considerably stronger than one manufactured using traditional methods - strong enough in fact to support the weight of a typical family estate car!



The assembly consists of a five part, as opposed to the current nine part, system and comprises of a traditional caravan floor, two laminated side panels, a solid laminated back panel and a new single span front and roof section.


The Unique Body Shell

The body shell panels are then clamped together with a bespoke aluminium extrusion framework that provides additional structural rigidity.

In addition to the extra strength this system provides the other main benefit of this new design is the absence of any external fixings which has a major impact on reducing the opportunity for water ingress into the body shell.

The outer aluminium extrusion houses the body shell panels and they are then held in place from the inside by a metal connecting bracket. The whole assembly is then locked together by a T-bolt fixing whilst a semi-circular plastic cap covers the fittings to give a neat interior finish.


Defence Against Water Ingress

To combat the problem of water ingress Bailey has introduced not one but two lines of defence into the Alu-Tech body shell design. The first line of defence is ingress prevention, where by every conceivable effort has been made to reduce the number of potential water access points, with a 90% reduction in the number of external joints and fixing points, thus improving the overall integrity of the protective shell.

The second line of defence is ingress management, minimising the impact any possible ingress may cause. This has been achieved with the development of timber free body shell panels, featuring a composite plastic internal skeleton, low absorbency buffer zones surrounding the windows and doors...

and an easy clean GRP inner wall.




Pegasus - one day, all caravans will be made this way











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