wanderBOX Shell Construction Review

Intro | wanderBOX Breaks the Mold of Shell Construction | Floor Construction | Wall Construction | The Results

wanderBOX wall and floor cutouts to show innovate design & construction.
Cutouts of Wall (left) & Floor (right)

Quality, Performance, Flexibility

People interested in wanderBOX often ask “what makes you different and better than alternative campers?” The simple answer is that wanderBOX RVs are mobile, off-grid, “tiny-homes” built using durable, inorganic materials with a hand-crafted build process that produces 10’s of units per year – with a price steeped in value.

High-volume RV manufacturers have a reputation for using inexpensive materials such as plywood and particleboard, combined with a design and build process structured to produce 100’s or 1000’s of units per year. This approach drives down the cost, innovation, and quality of RVs.

When searching for the dream RV, people are naturally drawn to floorplans, on/off road capabilities, water-solar-fuel capacities, etc. But how do you determine the performance and durability of an RV? Similar to other sophisticated solutions, quality is determined by design, materials and build process.

wanderBOX “Breaks the Mold” of Shell Construction

Some RVs use a fiberglass shell produced from a mold. They are lightweight and provide better insulation than the typical, lower cost, wood/aluminum shells. However, a shell from a mold is committed to specific placement of windows and doors – and requires a new (expensive) mold to accommodate a slightly different or completely new shell design.

The wanderBOX shell is a combination of inorganic, lightweight and durable materials delivering excellent structural integrity, outstanding insulation from climate and noise, and excellent fire resistance performance.

Additionally, and very important to customer-unique needs… our non-mold shell design supports flexibility in window /door placement. This means we can better “dial-in” a floorplan configuration with a door in the front or back of a wanderBOX!

A great example of door/window flexibility is evident in our Outpost 29 Floorplans: The Kane Creek is rear-door design, and the Pucker Pass has a front-door design. Which is pretty awesome!

Floor Construction

  • Coosa, a “fiberglass plywood” used extensively in marine industry.
  • 2″ Sub-floor held up by pultruded fiberglass I-beams and C-channel for plumbing & electrical, finished off with R-13 bat insulation filler.
  • 2″ Polyiso insulation layer, skinned with FRP.
  • 2″ Aluminum honeycomb layer, skinned with FRP.

Wall Construction

The Results

  • Lightweight & Excellent Structural Integrity
  • High Insulation R-Values: Wall R-15 & Floor R-25
  • Fire, Mold and Water Resistant
  • Excellent Build Foundation for Interior

Fun Fact: Honeycomb aluminum is used extensively in the aerospace industry in the construction of Helicopters, Planes, Space Station

Above: wanderBOX Outpost, driver-side, close-up view of the exterior wall with designer-wrap and windows. #wanderboxcamper

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