Showroom in Elmshorn from above with expedition vehicles and shop area
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Coachbuilding

How your expedition vehicle comes about – and why we build it exactly this way.

Advice and configuration

Listen first, then plan

An expedition vehicle is not an off-the-shelf product. Before we talk about floor plans, we want to understand how you travel: where, for how long, with whom and in what conditions. Only then does it become clear which vehicle really suits you.

  1. Identify your needsDestinations, people, seasons, driving licence, budget
  2. Settle the basicsChassis, size class, base floor plan or new design
  3. ConfigureChoose materials, technology and equipment in the configuration room, checked on the 3D model
  4. Quotation and purchase contractBinding quotation, purchase contract with payment schedule and build time
Request an advice appointment

Design

3D planning on screen

Your vehicle before it is built

We first plan every living cabin completely in 3D. This makes your ideas tangible as early as the consultation: we try out variants, show proportions and coordinate materials and colours. You see not only what is possible, but also why some ideas work less well in practice. At the same time, the model is the reliable basis for our production, so that in the end exactly what we planned together is built.

  • Complete 3D planning of every cabin
  • Variants live during the consultation
  • Proportions visible in advance
  • Materials and colours coordinated
  • Precise basis for production
Walk-through of the living cabin in the 3D model

Chassis / add-ons

The foundation for every journey

We don't just take over the base vehicle, we make it ready for travel. The overview shows what we build on the chassis and around the vehicle. Each number leads to a detail photo with an explanation.

Side view of a Kerkamm EX 592 on MAN 4x4 with numbered add-ons
Roof rack and branch deflectors above the cab in the design drawing
Detail 1 of 12

Branch deflector

Protection for your living cabin and the cab. Off-road or on narrow roads, a branch can quickly get in the way – this way it simply glances off. For us, a must on any real world-travel vehicle.

Detail 2 of 12

Ambient lighting

Bright as day at the touch of a remote: the ambient lighting illuminates the entire area around the vehicle – when manoeuvring, when working in the dark and for added safety.

Detail 3 of 12

Walk-through

From the cab straight into the cabin without getting out. In bad weather or danger, you simply drive off. The bellows absorb the movement between cab and cabin.

Detail 4 of 12

Additional lighting

Driving lights and light bars for night driving on unlit tracks, properly integrated into the vehicle electrics and approved.

Detail 5 of 12

Front protection bar

Protects the radiator, headlights and cab and takes additional lights on request.

Rear carrier with motorcycle and spare wheel in the design drawing
Detail 6 of 12

Rear carrier

Spare wheel lift, motorcycle and bicycle carriers, stainless steel boxes: at the rear we stow what has no room inside. Every carrier is designed for the vehicle and checked for weight and axle load. View all systems

Detail 7 of 12

Folding underrun protection

Folding underrun protection for a maximum departure angle off-road. Unlocked and folded up quickly and easily in two simple moves.

Detail 8 of 12

Stainless steel storage box

Robust stainless steel storage boxes along the chassis provide extra space for everything that can stay outside: accessories, tools, snow chains or recovery equipment. Firmly locked and well protected from water and dirt, with an integrated outdoor kitchen on request.

Detail 9 of 12

Levelling jacks

Hydraulic jacks level the vehicle and lift it for a wheel change. More about levelling jacks

Detail 10 of 12

Chassis preservation

The frame and add-on parts are cleaned and permanently sealed before the body goes on. This protects against rust from salt, mud and stone chips.

MAN TGS auxiliary diesel tank 400 l
Detail 11 of 12

Additional tanks

More range, more independence: with a second diesel tank, you fill up where price and quality are right and always have a reserve on board in remote regions.

Detail 12 of 12

Central tyre inflation system

Low pressure in the sand, full pressure again on tarmac – conveniently via quick couplings and a hose station per axle.
Proven technology from ti.systems.

Cabin construction

Warm in winter, cool in the desert

We rely consistently on GRP sandwich cabins: no wood that can rot, no metal that rusts, and a construction that can also be repaired on the road. Each number leads to a detail photo with an explanation.

Detail 1 of 9

Roof hatches

Burglar-resistant roof hatches from KCT or Outbound bring light and air into the cabin, even in the rain in ventilation mode.

Detail 2 of 9

Storage flaps

Large flaps for storage that can be reached from outside: chairs, tools, recovery gear.
Protected by burglar-resistant, multi-point locking mechanisms.

Detail 3 of 9

Cabin mounting

Our cabin mounting combines enough flexibility for off-road use with the rigidity needed for safe driving on road and track. Deliberately no diamond or three-point mounting: the body stays calm and stable, yet there are still reserves for demanding terrain.

Detail 4 of 9

GRP sandwich wall

GRP sandwich, free of thermal bridges and superbly insulated with a wall thickness of 53 to 60 mm. Thanks to the screw layer inside and out, furniture and add-on parts are screwed rather than glued: permanently secure and changeable at any time. And if something does happen: GRP can be repaired.

Detail 5 of 9

Entrance door

Stainless steel hinges and multi-point locking, secure and burglar-resistant.

Detail 6 of 9

Low entry

The lowered entrance does away with pull-out ladders and is simply comfortable. Getting in and out becomes safer, even with luggage and after a long day.

Detail 7 of 9

Door to the cab

The living cabin has a fixed door to the passage to the cab.
In addition, a flap in the cab dampens driving noise and provides extra insulation.

Detail 8 of 9

Windows

Burglar-resistant KCT-HartGlas® windows with blackout blinds and insect screens, fitted flush into the wall.
Alternatively, and when weight matters, we also choose products from Outbound.

Detail 9 of 9

Edge profiles

All-round profiles protect the edges of the cabin and seal them permanently. They also provide additional protection against external impacts.

Two constructions: Light and Standard

Standard cabin

The full construction for long journeys and extreme climate zones. Thicker walls keep out frost and heat alike, and the cabin also carries heavy fit-outs and add-ons. We deliberately build with GRP rather than aluminium: damage can be professionally repaired at any time, which is much more complex with aluminium cabins.

  • GRP sandwich, 59 mm wall thickness
  • For all climate zones, from −30 °C to +50 °C
  • Built free of thermal bridges
  • Screw layer inside and out: furniture and add-on parts screwed rather than glued
  • Repairable, even after many years
  • Top-quality windows from KCT or Outbound
  • Doors and flaps with multi-point locking for maximum security
  • Low entry, the most comfortable way in and out

Light cabin

The lighter construction for vehicles where every kilo counts, especially alcove vehicles. The same quality and the same requirements as Standard, but with targeted weight savings: through the design, different foams and a screw layer only where screws are actually used. Large alcoves bring their own requirements: their weight and leverage must be transferred safely into the walls. For this we have a well-thought-out structural solution that stays stable and still keeps weight down.

  • GRP sandwich, 53 to 59 mm wall thickness
  • Weight saved through design and adapted foams
  • Screw layer inside, targeted at the fixing points
  • Design suited to large alcoves
  • Built free of thermal bridges
  • Repairable like any GRP cabin
  • Lightweight Outbound windows and components, with real glass

Furniture construction

Built for the track, not for the living room

Furniture in an expedition vehicle is stressed quite differently from at home: vibration, twisting, temperature jumps. That is why we plan and build every piece of furniture in our own joinery and design every joint for it.

  • Rear ventilation concept. All furniture stands away from the wall. Air circulates, no condensation collects, mould has no chance.
  • Light yet stable. Poplar plywood and concealed joints save weight without creaking after years.
  • Household-quality fittings. They last thousands of track kilometres and can be replaced worldwide.
  • Nothing rattles. Soft-close push locks and secure catches, even on corrugated tracks.

Technology overview

Everything in view

Simple. Accessible. Reliable.

Above all, technology in an expedition vehicle has to work on the road, far from any workshop. That is why we rely on proven systems from renowned manufacturers, with redundancy where it makes sense, and install them so that they remain easily accessible for maintenance and repair. Technical gimmicks and overcomplicated solutions are not what we aim for. When in doubt, we choose the simple, robust solution that can be understood and repaired anywhere in the world.

The following chapters show what this looks like in detail.

  • Proven components from renowned manufacturers
  • Redundant systems where it matters
  • Easily accessible for maintenance and repair
  • Simple, robust solutions instead of gimmicks
  • Repairable worldwide

Water systems

Clean water, everywhere

On long journeys, water is one of the most important resources. We make our tanks to measure from 10 mm thick plastic panels rather than using thin standard tanks. They sit frost-protected in the heated interior, firmly integrated into the furniture. Multi-stage filters before and after the tank ensure good water quality, with components from premium manufacturers such as WM Aquatec, Goodguards and the Helion reactor.

Depending on the floor plan, 200 to 800 litres are possible. With a dry separating toilet, there is no need for black water and flushing water tanks, and the space goes into even more fresh water. Winter has been thought of too: the entire system can be drained completely and conveniently.

  • Custom-made tanks of 10 mm thick plastic
  • Installed frost-protected inside
  • Baffles, pressure sensors and maintenance openings
  • Industrial ball valves and large cross-sections
  • 200 to 800 litres, depending on the floor plan
  • Multi-stage filtration before and after the tank
  • Reverse osmosis system or a tap with UV-disinfected water on request
  • Filling by hand or by pressure filling
  • External water compartment with all shut-off valves
  • Fully drainable: drain valves at all low points

Heating systems

Cosy at −20 °C

As a starting point, we rely on proven Truma air heaters. If you want more comfort, choose hydronic heating from Wallas or Timberline with Alde convectors, with underfloor heating on request. We often install a second, independent heater, for example from Autoterm, so that it stays warm even if one system fails. And we direct warm air specifically behind seat cushions and under mattresses: this keeps these areas dry and free of moisture.

We still offer gas heating. However, more and more customers are choosing a completely gas-free vehicle with diesel heating. Thanks to altitude kits, diesel heaters now work reliably even where previously only gas was an option.

  • Truma air heating as a starting point
  • Hydronic heating from Wallas or Timberline
  • Alde convectors for even warmth
  • Underfloor heating possible
  • Redundant auxiliary heating, e.g. from Autoterm
  • Warm air behind cushions and under mattresses
  • Gas-free with diesel or classic with gas
  • Altitude kits for diesel heaters in high mountains

Energy systems

Self-sufficient, even for weeks

We build our energy installations as complete systems from Mastervolt or Victron. We deliberately stick to one manufacturer so that all components work together reliably. High-quality lithium batteries, a second alternator and plenty of solar power on the roof make the vehicle largely independent of the mains, even fully electric with induction, oven and washing machine.

Several layers of protection prevent the batteries from suddenly shutting down or falling into deep sleep. Should a battery ever shut down, a power connection is enough and it comes back on its own.

  • Complete systems from Mastervolt or Victron
  • High-quality lithium batteries with several layers of protection
  • Second alternator for fast charging while driving
  • Solar modules with up to 460 Wp per module
  • Inverters up to 7,000 W and more, also redundant
  • Multi-voltage chargers for 110 and 230 volts worldwide
  • Clearly laid-out 230 V distribution with circuit breakers and documentation

Project process

From chassis to service

This is how your vehicle comes about in our workshop in Elmshorn. Browse through the build step by step or show all steps at a glance.

Step 01

Advice and configuration

With us, every vehicle begins with listening. We give open advice, show possibilities and limits, and remain your dedicated contact from the first design to well beyond delivery.

Step 02

Design

Every project starts with one of our proven floor plans. We design your wishes into the vehicle in 3D, adapt details and make the result visible before anything is built.

Step 03

Chassis delivery

We order the right base vehicle from the manufacturer or take over your own.

Step 04

Fitting the walk-through

The rear wall of the cab is opened, and the walk-through is sealed and framed.

Step 05

Building the cabin

Fit the subframe, mount the GRP cabin, install windows and doors.

Step 06

Fitting the tanks

Diesel, fresh water and waste water tanks are fitted.

Step 07

Furniture – alternating with technology

Carcasses, substructure and bed are made in the joinery and fitted.

Step 08

Technology – alternating with furniture

Water, heating and power lines are laid, batteries and charging technology installed.

Step 09

Testing

Test drives, leak test, gas inspection and TÜV approval.

Step 10

Delivery

Handover in Elmshorn with a detailed introduction to all systems.
Of course, you also receive an individual operating manual.

Step 11

Support on the road

Maintenance, retrofitting and remote help, even on the other side of the world.