Caravan World 563 - Sampler Edition

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Issue 563 | On sale may 4, 2017 $9.95 (inc GST)

AL-KO’S

TOW TEST High Country hijinks!

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Strap yourselves in as we take you behind the scenes on the first leg of AL-KO’s Toughest Tow Test!

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I Words Michael Borg

Above: Our crew of tough toys rolls into Kevington during Part 1 of the Toughest Tow Test.

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t’s not every day you see a convoy of caravans battling through the guts of the Victorian High Country. In fact, the word ‘crazy’ might come to mind if you spend more than a second thinking about it! Nothing says real world torture-testing like an 18ft caravan conquering everything from harsh ruts and corrugations to rocky river crossings with more than a few steep hill climbs, tight switchbacks and soft creek beds thrown in.

But that’s exactly what we did for AL-KO’s Toughest Tow Test. Using vans fitted with the right running gear and an army of technical experts on board, the impossible became possible...

Over the course of a week, we safely navigated both on-road and offroad test tracks showcasing the best of the High Country; first with on-road vans, and then offroad vans, in tow.

In truth, you wouldn’t normally think about dragging a two or three tonne caravan through the tracks we did, but these were no ordinary vans.

The contenders – a New Age Wallaby, Avan Aliner Adventure Plus, Golf Savannah 499, Coromal Pioneer XC, and JB Caravans Scorpion, were all kitted out with AL-KO running gear, including the latest offroad ALKO Enduro Outback suspension or the on-road AL-KO Roller Rocker leaf spring setup, and the

all-new AL-KO Off-Road coupling or a standard AL-KO on-road ball coupling, and a bunch of other goodies to prepare them for the journey.

But the big question: would this be enough to get them through a test track most caravanners would never attempt? We’re not ones to shy away from an epic adventure and, after a week of pushing these vans and their gear to the absolute limit, it’s fair to say AL-KO knows how to prove a point!

In this issue of CW, we take you behind the scenes on the first leg of the trip where we put the on-road New Age Wallaby and Avan Aliner through their paces in terrain which would test their limits – and that of their AL-KO gear.

THE GATHERING A mammoth trip of these proportions requires a great deal of planning and forethought, especially when safety is at stake.

After all, it doesn’t take much for things to go horribly wrong with a caravan in tow among some of Australia’s steepest hills. With remote terrain lying in wait for us, we took our time to create a route which encompassed the very best the High Country has to offer.

Myself and Anthony ‘Macca’ McDonald – a long-time outback adventure guide who has taken more caravanners and campers through Australia’s harshest terrain than most people

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have had hot dinners (if you were on one of Macca’s trips, chances are he cooked the hot dinner for you, too!) – set off for Dargo, the most remote town in Victoria, to head bush and map out a suitable route worthy of the Toughest Tow Test label.

A few months later, it was go-time!

The eager crew – including CW tow-testers, photographers, videographers, AL-KO engineers and staff, and some assorted adventure junkies – met in Dargo for Happy Hour at the Dargo River Inn, which marked the start of our AL-KO Toughest Tow Test adventure.

Oh, and here’s a little tip if you ever make it to the Dargo River Inn; if you see the publican

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dressed in nothing but bright pink lycra and a majestic blonde wig, there’s a better than average chance he’s lost another bet!

Although, it’s rumoured he does this on purpose…but who are we to judge?

Clockwise from above: High Country explorers, everyone say ‘Jump!’ on three; Take on the alpine roads in a Hema Maps 76 Series? No worries!; There’s no better spot for a thorough tow-test than Vicco’s High Country.

THE ADVENTURE BEGINS As soon as dawn broke, we were up and at it, ready to hit the road. The goal for the first leg of this trip was to take our two blacktop tourers, fitted with onroad AL-KO products, along a route tradervs.com.au

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Clockwise from above: Our LandCruiser took on tow duties for the New Age Wallaby; Spectacular country came free with the challenging conditions; Rough terrain coming up.

WIN! tHE ULTIMATE TOUGH TOWING KIT, VALUED AT

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”Not all vanners want, or can afford, a fullblown offroad rig but still want the option to chase adventure across the cattle grid” that would test their abilities on the bitumen and graded dirt roads – and we threw a few corrugations into the mix just for fun!

Not all vanners want, or can afford, a fullblown offroad rig but still want the option to chase adventure across the cattle grid. Our convoy consisted of CW’s Toyota LandCruiser 79 Series towing the New Age Wallaby, Hema’s Map Patrol LC76 Series towing the Aliner, and two Nissan Patrol GUs acting as support vehicles and troop carriers.

To see how the AL-KO systems performed, we explored countless tracks around Dargo and surrounds, passing through the sleepy hamlets of Newry, Boisdale and Brigalong before heading for Licola.

We then ventured onwards to the cute little town of Jamieson to the west, via just about

every winding road and dirt track we could poke our noses down. This part of the route followed a tricky 93km stretch on dirt and gravel – including spectacular alpine vistas of the Macalister River valley and its mountain ash and snow gum forests. Along the way, we saw some of the best views and vantage points known to man, and that’s no exaggeration. We even encountered a herd of cattle grazing along the side of the road – a pretty uncommon sight in the High Country these days!

The dust was thick and the corrugations were relentless along this stretch and, to be totally

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honest, I remember thinking to myself: “This is supposed to be the easy part; what the hell have we got ourselves into?” But, in the end, we made it, wholly unscathed, to an absolute cracker of a campsite at Skipworth Reserve in Kevington, about 10km outside Jamieson (which is, of course, right on the Jamieson River).

The track in was very bumpy, and while it wasn’t hard-core offroad terrain, it just goes to show you the calibre of campsites that a welldesigned suspension system can give you the confidence to venture into. One thing’s for sure – there’s nothing quite like rocking up to camp in the late afternoon, getting a campfire crackling, and enjoying a few cold ones as the sun slowly

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sets over the hills. It was Macca’s shout for a feed that night and, after hearing whispers of his skill behind a skillet for years, I was champing at the bit to find out what was on the menu.

Unfortunately, poor Macca ended up a little ill that night, which saw him taking over the most luxurious caravan-king-size bed on the trip!

Not to worry though – his brother Tim had things covered, with a potato salad fit for kings while our photographer (and self-proclaimed fishing expert) Jack knocked up barramundi fillets thick enough to feed half the army. Add in a few burnt hunks of cow cooked straight over the coals by yours truly, and you could say we were living the dream. The following day, we

Clockwise from top: You can bet a few tall tales made an appearance ‘round this fire; Preparing for another day on the road; Small towns, big hearts in the High Country.

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Clockwise from top: River crossings in this part of the world posed few problems; Emile from AL-KO managed to find a bit of time for a quick fish one beautiful morning; Borgy takes it all in during a rare moment of rest.

explored Kevington before taking a detour to the old-world towns of A1 Mine Settlement and Gaffneys Creek, before setting off for Mansfield, in the foothills of the Victorian Alps and home of Victoria’s traditional cattlemen.

WHAT DID WE FIND? One thing’s for sure, after a week beating around the High Country with them, I’ve got no qualms in saying the team at AL-KO sure knows how to test their gear in the real world.

But to be honest, this equipment is put through the most rigorous of trials well before we ever got our mittens on it – in research and development, and by countless other caravanners towing their

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rigs around the country. So it wasn’t really a matter of ‘if’ the gear was up to the task, it was more about getting out there and showing the world just how capable it really is – point taken, guys!

We trudged through the bowels of the High Country, and despite having a million and one challenges thrown our way, we came out the other side in one piece. Well, mostly! The vehicles broke down, and most of us were absolutely buggered by the end of it, but you know what?

The AL-KO gear never let us down, and that’s saying something!

To find out how the offroad rigs handled the tougher terrain, stay tuned to the next issue of Caravan World (on sale June 1) for part two of ALKO’s Toughest Tow Test – the Offroad Edition! tradervs.com.au

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DANGERZone

Tick all the option boxes and Zone RV’s latest Z-21.6 further resets large off-roader van standards.

Pics NATHAN DUFF

In brief...

21ft 6in, high-tech offroader Custom-built with stacks of optional extras Automotive and luxury marine standards construction and finish

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Tested

Zone RV Z-21.6 Off-Road

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T

he greatest compliment you can pay any caravan manufacturer is to buy another van from them. Coming hot on the heels of its debutante victory at Caravan World’s signature caravan shootout, Best Aussie Vans in 2016 ($100K-plus category), it’s one that has already been paid to Queensland’s Zone RV. The 6.55m (21ft 6in) Z-21.6 Off-Road that we’re reviewing here replaced an earlier 6.25m (20ft 6in) Z-20.6 model for a Sunshine Coast businessman. Another impatient Zone RV customer, who was facing a wait of up to six months for a new van, made the upgrade a practical and economical proposition for the businessman by buying his pre-loved Z-20.6.

“While our owner was very happy with his original 20ft 6in Zone, he and his wife really liked the extra space in the Z-21.6 Off-Road,” Zone’s marketing manager Denise Missen explained.

“They love the luxury of having another foot in their latest van and the second time around they had more time to think about the additional upgrades and options they wished they had ordered on their original Z-20.6 Off-Road.”

The upgrade is a further acknowledgement that the Coolum Beach manufacturer has tapped into a niche in the Australian caravan market, where customers are looking for automotive or marine standard materials and manufacturing in caravans and are prepared to pay for it.

In this case, the end cost of $141,465 for the Z-21.6 is around $28,500 above the model’s base price, but if you’re shopping in this market, you will know that this is ballpark money for a tough offroader with this level of features. The fact that Zone RV can already play in this lofty league after only a couple of years on the market is testament in itself to its quality and the wordof-mouth endorsement the company’s customers have given it to date.

The Z-21.6 Off-Road we reviewed certainly showcased just what this new kid on the block is capable of. From the outside, it looks smart with its smooth white walls with curved edgecapping but is disarmingly conventional. Only its unusual ‘beaked’ drawbar, which curves

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WORDS MICHAEL BROWNING

Clockwise from right: The screen door is a funky hourglass design; Zone RV’s timberless contruction makes it an impressively rigid monocoque structure that can handle the rough stuff; The optional Vehicle Components’ Cruisemaster XT-Air Bag Suspension Stage 4 is a premium addition for offroading; When it’s time to fire up the barbie, simply slide it out and you’re away; The upgraded suspension incorporates two telescopic shocks per wheel.

Measuring up Pros Hi-tech construction Offroad strength Great ground clearance Long-term touring ability

Cons No lithium battery for the price No built-in pole carrier No merit plug for portable solar panel

down to the hitch for improved ground clearance and is gusseted underneath for extra strength, initially caught my eye.

The all-fibreglass composite body has impressively clean styling and is relatively unencumbered, devoid of the ‘bling’ of many of its rivals. Grey Raptor urethane coating is used liberally on the lower body sides, instead of checkerplate, to repel stones and the same twopack heavy-duty coating has also been applied to the chassis, the A-frame, toolbox, stoneshield frame, wheel arch moulds, rear bumper and pole carrier – in fact, anywhere that could be vulnerable to stone or scrub damage.

Zone RV co-founder Dave Biggar said the Raptor coating adds less weight than the

Tested

Zone RV Z-21.6 Off-Road

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Zone RV Z-21.6 Off-Road Weights and measures Overall length 9.5m (33ft 4in) External body length 6.6m (21ft 6in) External body width 22.40m (7ft 10in) Travel height 3.1m (10ft 2in) Internal height 1.98m (6ft 5in) Tare 2820kg ATM 3500kg Payload 680kg Ball weight 185kg

External Construction Timberless construction with 32mm fibreglass floors and solid foam core walls and roof Chassis 150x50mm RHS DuraGal steel with 3mm Raptor coating Suspension Vehicle Components XTAirbag with Stage 4 Auto Level Control Brakes Electric-hydraulic disc Wheels/tyres 18in alloys with 275/70/ R18 light truck tyres Water 2x100L (fresh); 1x100L (grey) Battery 3x120Ah AGM Solar 400W roof-mounted flexible lightweight panels Air-conditioner Truma Grande Gas 2x9kg Stability control Dexter Kitchen Slide-out Bushmaster RV gas barbecue

Internal Cooking Swift 500 Series combo fourburner, grill and oven Fridge Waeco 218L compressor Microwave Samsung Toilet Cassette Shower Fibreglass Lighting LED Hot water Truma gas/electric Washing machine Daewoo 2kg wallmounted front-loader

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Options fitted

500mm drawbar extension; Thule bike carrier; Rear roof folding 10-step access ladder; Anti-flap kit with wall-mounting brackets; Black awning with black awning arms; Cruisemaster XT-Air Bag Suspension Stage 4; Electric-hydraulic disc brakes; Second rear spare wheel mount; 18in LandCruiser Sahara matched black alloy wheels with 275/70-18 tyres; Separate Surflow 12V water tank isolation system with three-way tap for drinking water; Additional 100L fresh water tank with aluminium tank armour; Third 120Ah AGM battery, plus 2000W inverter; Additional 100W solar panel (total 400W), Enerdrive 2000W ePRO inverter with auto switching; Eberspacher 12V diesel air heater; 2 additional Sirocco wall-mounted 12V fans; External Bushmaster RV barbecue, articulating side and utility drawer; Extra external LED lights; Lounge area bed insert to convert seats to a single bed; Waeco 218L compressor upright fridge/ freezer; Under-bed four-drawer storage module; Additional four drawers in vanity cupboard under sink; VANSAT Bluestar Automatic TV Satellite system including decoder

Price as shown $ 141,465 (drive-away, Qld)

More information To enquire about this caravan, please visit www.caravanworld.com.au/spec or phone 1300 134 446

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Zone RV Z-21.6 Off-Road

UNDER THE SKIN However, it’s not until you see how these caravans are put together that you begin to appreciate their significant difference to other caravans.

The millimetre-perfect accuracy to which Zone RVs are being built is truly impressive. Each van begins with a CAD drafting, from which all key components are CNC-cut – nothing too radical there – but it’s what happens next that makes the difference.

In most caravan factories, the caravan moves along a production line, with each team adding more parts. But in the case of a Zone RV, the

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equivalent amount of checkerplate and can easily be touched up if scuffed or damaged. It certainly looks smart and complements the Zone RV’s exterior styling.

chassis is anchored to a rigid metal jig – just like a chassis aligner in a top-quality automobile repair facility – to ensure all key dimensions are maintained during the construction phase.

All supplies are then brought to this bench on movable trolleys and the caravan is only unbolted when the major exterior and interior components have been fitted. This avoids any potential movement of the structure, ensuring that the finished product remains true to its original CAD dimensions.

Zone RV boasts about its ‘timberless’ monocoque construction with good reason. In most caravans, a plywood floor is glued to the steel chassis, the vinyl flooring is then applied and the walls are then framed and screwed or bolted to this base.

With the Zone RV, the floor is 32mm thick infused fibreglass, reducing the number of chassis cross-members required.

Instead of timber, the furniture is framed from aluminium extrusions and when it is all in place, the walls and roof are bonded directly to both the floor and cabinets, ensuring that the result is a very rigid, monocoque structure.

You might ask why this is important, given that more conventional caravans from other quality Australian manufacturers seem to do

FRIDGE

Clockwise from far left: A 500mm drawbar extension allows these owners to carry two jerry cans and an optional Thule bike carrier; Smart grey Raptor urethane coating is used on the lower panels instead of checkerplate to reduce weight; The classy grey and white exterior colour scheme extends inside; It’s a quick trip up the rear ladder to access the 400W roof-mounted flexible solar panels;

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telescopic shocks per wheel, and incorporates automatic level control to make it easier to set up on a sloping site.

DEVIL IN THE DETAILS While looking underneath, I took time to appreciate other Zone RV details, like the relative absence of heavy steel chassis crossmembers, the aluminium-shielded water tanks and the way all vulnerable piping is tucked away high and well out of harm’s way from snagging or stone strikes.

It’s also interesting to see the way Zone RV deals with the mandatory ventilation for caravans fitted with internal gas appliances.

Instead of ‘breathing’ through the lower section of its solid Dometic security door, there are twin circular extractors to the rear of the water tanks that are designed to minimise dust intrusion.

Other details, like the way the enclosure for the large 218L Dometic compressor fridge is fully dust-sealed from the interior of the van yet has a large ‘chimney behind it to breathe in hot weather, shows an impressive eye for detail.

SUSTAIN YOURSELF Above: The central lounge offers a very comfortable space for two for breakfast, lunch and dinner.

pretty well, but the difference can be appreciated on the road.

A basic Z-21.6 tips the scales at a Tare weight of around 2535kg and can offer a payload of close to a tonne or more, if required. Because of its many upgrades, the Z-21.6 we reviewed was 285kg heavier at 2820kg Tare, but still boasted a good carrying capacity of 680kg.

What this means on extreme rough road conditions is that you can tow it all behind a large, locally-available 4WD like a LandCruiser or Land-Rover, providing a very rigid platform for the tandem trailing arm suspension to deal with the undulations.

In swapping to the longer Z-21.6, our test van’s owners took the opportunity to upgrades from already rugged Cruisemaster ATX coil spring to Vehicle Components’ premium XT-Air Bag Suspension Stage 4, which also comes with twin

Ratings 1. Value for money 2. Towability 3. Liveability 4. Setting up and hitching 5. Suitability for intended touring 6. Layout 7. Quality of finish 8. Build quality 9. Creature comforts 10. Innovation 11. X-Factor

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Inside, Zone RV has taken full advantage of the Z-21.6’s length to make it roomy and workable for long-term travellers.

Unlike most caravan manufacturers, which use the term ‘offroad’ to refer principally to the caravan’s strength, damage proofing and ground clearance, Zone RV also uses this terminology to encompass sustainability in remote areas.

Upgrades, including a third 120Ah AGM battery, a fourth 100W roof-mounted solar panel and a 2000W Enerdrive inverter, ensure that the owners of this Z-21.6 will be able spend quality time off the grid; although, if it was mine, I would prefer the extra solar panel to be portable rather than roof-mounted, allowing it to follow the sun if camped in the shade.

An extra 100L of fresh water storage takes the total volume of the review van to 300L and, combined with 100L of grey water storage, should be plenty for stays of a week or more. The optional Shurflow 12V water isolation system is able to deliver fresh drinking water even if you fill your tanks from a river.

Good storage space is another thing you need in a true offroad van, as the nearest supplies may be weeks away.

The large A-frame storage box is large enough to hold a generator on one side, which can be accessed through a side door, plus room for hoses and power cables and a single jerry can holder on the other side.

The fuel tank for the optional Eberspacher diesel space heater, twin 9kg gas cylinders and the optional Thule bike rack are protected on

Tested

Zone RV Z-21.6 Off-Road Left: Hinged overhead kitchen cupboards allow space for items and also house the entertainment system.

Below left: Drawers upon drawers will make travelling chefs pretty happy, and the van also boasts an optional Shurflow 12V water isolation system to deliver fresh drinking water.

the 500mm extended A-frame by a truck-mesh stone screen with large mud flaps that are hanging beneath.

A Bushman RV Explorer stainless steel barbecue slides out of the front left side locker to supplement the inside kitchen, while the corresponding locker on the other side of the body provides more storage room.

Unlike some caravans, the Zone RV’s upper inside walls aren’t lined with the cupboards that you find in most other caravans and this, combined with its large windows front and sides, gives the Z-21.6 an open, airy feel inside.

Zone RV prefers drawers to cupboards because they locate things better in offroad

All-road Zone on the way As part of ambitious plans to grow the business from its current rate of seven completed caravans a month, Zone RV plans to introduce a new three-model range of all-road caravans by mid-year.

Called the ‘Venture Series’, the new models will weigh less than existing Zone RV vans of similar length, thanks to their lighter chassis, all-road Vehicle Components CRS, rather than heavier ATX suspension, and a lower level of standard spec.

As Zone RV defines it, a true ‘offroad’ caravan must not only have the ability to deal with difficult terrain, but also allow its occupants to live ‘off the grid’ for at least a week at a time.

However, the Venture Series is not designed to go to the same remote areas, or be away from a mains power supply for as long, reducing the need to carry as many batteries, solar panels, batteries and water tanks.

More importantly, it will bring Zone RV’s timberless construction, unique one-piece composite floor and upper body panels, aluminium framed and PVC coated cabinetry and signature high-tech bonded monocoque construction within the reach of many more caravanners looking for the same level of quality and precision as in their offroad models.

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The new range will start to roll out of the company’s current and increasingly crowded factory by June, with three tandem axle models offered initially; the ZV-18.6, (18ft 6in), ZV-20.6 (20ft.6in) and ZV-21.6 (21ft 6in).

The aim is to keep the full Venture range under 2.3t Tare, while ensuring that all models have a minimum

payload of around 800kg.

To make this new volume possible, Zone RV is planning to move into new and larger premises in the Coolum Beach area where all operations can be carried out under one roof. The company is already feeling the space pinch at its current production rate, with cabinetry being built in a second factory in the area. tradervs.com.au

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Tested

Zone RV Z-21.6 Off-Road

Above: The van’s large interior windows allow oodles of natural light inside. Above right: How good is this optional four-drawer cabinet at the foot of the bed?

travel and thanks to optional four-drawer cabinet under the foot of the bed, a similar optional chest of drawers in the ensuite and a huge triple-decker pantry beside the 218L Waeco compressor fridge, there is no shortage of space for the supplies or clothing that you might need

on an extended remote area trip.

The furniture is also smart and modern with PVC coating over aluminium making it light, yet attractive. Quality hardware is used on the cabinet drawers, while concealed catches are fitted on the upper cupboards.

Another feature specified by this van’s owners with their upgrade was an infill cushion for the U-shaped dinette to convert it quickly into an additional, large single bed.

It was interesting to review a caravan that has been built specifically by its owners to further improve on what is already a quality offroader and we applaud their choice and good taste.

Quite simply, Zone RV with its option list gives anyone looking at the serious end of the off-road caravan market another ‘must’ to add to their shopping list.

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