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The Alu-Tech bodyshell construction system is the most significant development in caravan production technology for over thirty years.

After having undertaken the most comprehensive product design program the industry has ever known, the Bailey development team has produced a construction system that is so unique that it has necessitated the commissioning of over 100 bespoke tools to build it and that features a design so advanced that it has 5 new patents pending.

This page explains how the Alu-Tech body shell came into existence, the people and ideas behind it plus the tremendous lengths that Bailey, in conjunction with its third party development partners, has gone to ensure that every aspect of the design has been thoroughly evaluated.

The result is a caravan that is triumph of engineering and technological advancement that offers real advantages of ownership.

The Design

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 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 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.

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.

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What it means to you

  • More weatherproof
  • Keeps you warm
  • Keeps you dry
  • More robust and more durable
  • More aerodynamic and inherently more stable


The All Weather Vehicle

Weatherproof Shell – “KEEPING YOU WARM”

  • High density polystyrene insulation for side and roof panels
  • Additional insulation of pipe runs and wheel box
  • As a result the shell is fully insulated shell to Grade III classification of EN1645-I
  • Keeping you warm in winter and cool in summer – all year round touring
  • Making it more economic to own and more environmentally friendly


Weatherproof Shell – “KEEPING YOU DRY”

First line of defence – ingress prevention

  • Use of a five-part panel system reduces exterior seams
  • Structural interlocking aluminium external framework with no external fixing points
  • Flush fit bonded windows and exterior service doors with no external fittings

Second line of defence – ingress management

  • Panels built using a timber free construction, incorporating a composite plastic internal skeleton, high density polystyrene insulation and low maintenance fibreglass inner wall linings
  • Panels incorporating low absorbency buffer zones surrounding window and doors



Off-road Testing

The team at Bailey Australia road-tested a Bailey Unicorn and Pegasus GT65 in outback Australia, boldly demonstrating the vans’ remarkable off-road capabilities, sheer strength and resilience to the harsh and often unforgiving Australian environment. WATCH as these two Bailey’s hold their own against locally-built rivals in South Australia’s dusty outback: