All Aluminum Cabinet Frames

• TIG Welded Joints
  • Designed for the sheer forces produced in a moving vehicle.
  • Rigid structures to prevent collapsing.
• Cabinet panels are fastened with machine screws
• Aluminum frames are mounted to the body of the van for SAFETY

The Stowaway Fold Up Bench (Seats 2)

• Meets FMVSS (“Federal Motor Vehicle Safety Standards”) rating for United States & Canada
• Installation method has been Pull Tested, & exceeds all safety standards

Aluminum: We use throughout our builds.

• Not all aluminum is equal. We use aerospace grade alloys & increased wall thickness when needed to create the perfect balance of durability, strength & lightness.

UV rated marine board

• Stands up to the elements without absorbing moisture.
• Doesn’t require edge band finishing or coatings to seal it & make it look good.  (These are 2 major points of failure we totally avoid.)

Top of the line vinyl flooring

• We’ve tested dozens of flooring materials & this is the best we’ve found thus far.
• The flooring material is only half of the durability equation. We also consider the compatible methods for adhering it.
• Will it stay adhered under extreme conditions? (Like: cold, heat, direct sunlight).
• What does it look like after heavy use? (Scratched, dented, under heavy items, after wet items, etc.)

Marine grade upholstery material

• Even our tweed includes a water proof layer, to prevent moisture from penetrating into the underlying substrate.

Lighter panel material

• Because our framing creates the needed structural support, we can use lighter panel material in many places.

Infrastructure Welded Joints:

• No fasteners needed for joints in the infrastructure.

Bolted to the body of Van for Safety.

• We bolt infrastructure directly to the body of the van. Using nuts, bolts & rivets.

Single sheet of upholstered aluminum

• Our overhead cabinets are made from a sheet of upholstered aluminum.
• Additionally, we attach UV rated marine board with machine screws directly to this aluminum.

We use machine screws tapped straight into the aluminum,

• For attaching our cabinet panels, hinges & drawer slides.

Real World Example: This is a peek into our design consideration process.  Below you’ll find a list of materials we considered using for cabinet infrastructure.

We were seeking material & assembly methods that would provide: lightweight, strength, sound deadening & 20+ year durability… Under the extreme forces of a driving vehicle that can be taken off-road. 

(Read about sheer forces on wood cabinets installed in a moving vehicle below)

TIG WELDED ALUMINUM: Is the best we’ve found thus far.

• The Lightest
• Strength far exceeds all requirements
• Rigid tube structures are safer
• Non-corrosive
• All Machine screws are on the outside panels. Easily accessed for tightening & maintaining. (No wood screws/nails that will rattle loose & no machine screws at inside joints to rattle loose.)
• Our Experience: TIG Welded aluminum infrastructure is the best material & assembly method we’ve found thus far.

8020 ALUMINUM: Heavier & impossible to maintain.

• Heavier
• Strength far exceeds all requirements (With proper aluminum alloy & while all screws are tight/secured)
• Can make rigid structures (while all screws are tight/secure)
• Non-corrosive
• Machine screws at every joint, make it impossible to maintain.
• Our experience: These screws come loose over time riding in a vibrating vehicle. Yes, even when using Loctite type screw adhesives.
• Big Challenge: When they do come loose, they are impossible to find and/or maintain/tighten again.
• EXAMPLE: Every joint inside a cabinet like the Galley, has 4 to 6 screws.  Our galley would need 150+ screws just to assemble the inside joints.
• Once loose, these hidden screws can: 
  • At best: cause rattling noises
  • At worst: cause a safety hazard 

STEEL: Corrosive & heavier than aluminum.

• Can be the heaviest (depending how it’s used.)
• Strength far exceeds all requirements
• Rigid tube structures are safe
• Corrosion causes rust & a break down of structural integrity. (Every tapped screw is an exposed steel corrosion point)
• If you use thick-wall steel, Machine screws can be tapped directly into the steel.  But thicker means heavier.
• Our Experience: Thin wall steel can be used for certain purposes, as long as it is coated properly & the coating is not likely to be damaged.

WOOD: When assembled with wood screws & nails is heavier & less durable than all other material/assembly method.

• Can be the heaviest. Especially when considering all wood cabinets need thicker wood panels to be equally rigid.
• Not very strong or durable under normal driving conditions. Under normal vehicle accelerating & breaking, the side to side sheer forces loosen wood nails, screws & glue.  Forces in a home are top down, but forces in an adventure van are top down when stopped & side to side while driving.
  (Example of force in a moving vehicle: A 100 pound item in a vehicle moving 30 mph, that comes to a sudden stop, becomes a 3000 pound force.)
• Wood joints with screws/nails are the least durable/safe
• Absorbs water & becomes damaged.
• Wood screws/nails will vibrate loose & damage the wood structure. Not maintainable/tighten-able over time.
• Once loose, these wood nails, screws & glue can: 
  
  • At best: cause rattling noises
  • At worst: cause a safety hazard
• Our Experience: Wood can be used as panels.  It is easy to work with & can be easily machined.  Don’t use for infrastructure & protect from potential water damage.

We’ve been making warranty repairs happen in DAYS NOT MONTHS!

Designed Different:

• Our Electrical System is like no other!
  It includes:
  • Smart system: All components are interconnected
  • Built-in Remote Diagnosis (beyond the component level)
  • Designed with high quality, readily available, off the shelf parts.
  • All of these design features mean:
    “If you have trouble, we can diagnose it remotely, source parts quickly & repair it in days . . . not months.”