Caravan review: Zone RV Expedition pop-top hybrid

Zone RV’s new Expedition delivers remarkable technology in a hybrid caravan with top-class equipment for remote travel and off-grid adventure.

In brief

• A compact hybrid with cutting-edge technology
• Can be set up for couples or two bunks for family travel
• At $158,000, it is remarkable value

The path to this latest Zone RV Expedition has been a steady climb through the testing and production of various models over the company’s eight-year history. With a comprehensive background in composite technology and boat building, the team is uniquely placed to deliver innovative and capable offroad vans. Recently, it has rationalised the model range into two full-height caravans and the new Expedition hybrid we see here.

As outlined in the Zone RV factory tour article in this edition, the Expedition is built like no other van. It takes its shape from moulds developed on a massive 3D printer and the various components, including the wall and roof, are vacuum moulded in the same way high-tech sailing boats are built.

About Zone RV

Based on the Sunshine Coast in South East Queensland, Zone RV operates from three large factories in a $7.5m investment dedicated to chassis manufacture, composite construction and caravan assembly. Zone RV is one of a group of companies that builds high-performance catamarans, lightweight aeroplanes and composite products in the ONE Composites facility. So, with such a broad array of businesses, there is a considerable depth of experience and technology to call on for new designs and improved building methods.

We had the chance to tour Zone RV's factory when we checked out this van, so click here to see what we discovered about this unique Aussie manufacturer.

Zone RV's build process

The Expedition’s unique construction starts with a computerised design sent to a 3D printer to make the plugs for the walls, roof and floor moulds. The printer was a $1.8m investment about two years ago, along with additional robotic equipment to modernise production. The four body components of two wall sections, the roof and floor bond together to form a caravan structure with optimum strength and sealing from dust and the elements. The front and rear walls are incorporated into the side wall moulds and meet in the middle at the ends to be permanently bonded in place. The unique aerodynamic shape minimises wind resistance, significantly reducing fuel use when towing. Zone suggests a 4L/100km fuel saving with a LandCruiser 300 Series compared to a full-height van.

The body bonds to the hot dipped galvanised chassis, which is polyethylene coated for added protection before the team installs Cruisemaster ATX Unleashed suspension. Brakes are electric over hydraulic discs at all four wheels and three 100L freshwater tanks and the proprietary sealed battery box sit high in the chassis rails.

The Expedition boasts a timber-free build with composite furniture around aluminium strengthening panels.

Up front is the signature drop-down drawbar with a Cruisemaster DO35 hitch. The images here show the drawbar’s minimalist look to accommodate only flammable essentials that must be stored outside the van. Compact hatches house a smaller 4.5kg gas bottle for the external barbecue with a poly diesel tank for the heater and hot water. An electric power jack is permanently attached at the drawbar, while two manual steadies at the rear keep the van from moving when parked.

That front storage hatch is a true winner. Taking up about 1.5m of body length, you would likely never fill it. Still, if needed, you can take advantage of the van’s nominal 1046kg carrying capacity as long as you balance the overall weight distribution. Shelves move around to suit your needs, and with access to both sides there's ease of access, so packing should be easy to organise. A couple of significant accessories reside on the driver’s side of the hatch. The WiTi Caravan Security System has an alarm and a GPS tracker, and there’s provision for a Starlink compatible connection for internet and phone access.

A rear bar is part of the chassis at the back, so it’s strong enough for a spare wheel and other equipment. A modular receiver can hold bikes and other equipment, and a set of MAXTRAX mounts to the side. Along the driver’s side, we see another vast storage compartment and a hatch for the bulk of the REDARC Electronics package. I like the quick access to keep an eye on things and the professional assembly straight from REDARC.

What outdoor living features does the Zone RV Expedition have?

In travel mode, the Expedition looks sleek and stealthy. Its low 2.61m (8ft 6in) profile matches a narrow 2.15m (7ft 1in) width best suited to navigating tricky tracks. Tandem wheels and chunky tyres big enough to swap with many tow vehicles add to the capable presence. Up top, the roof line includes aerodynamic recesses for the solar panels, so only the low-profile (optional) air-conditioner pokes above the military-style roof rails. The stealthy impression comes courtesy of the pop-top roof, of course, and the modern look aligns with other Queensland builders who have embraced the pop-top concept for a wind and tree-line-avoiding path with a low profile and aerodynamic shape. Yet it manages to maintain a distinctive style, and despite its compact 17ft living space, the van has a significant road presence thanks to the oversized storage space integrated into the forward section.

In true hybrid fashion, the Expedition is oriented to outdoor living. It has an extended kitchen under a lifting hatch that offers quick access and protection from the elements while preparing meals. In addition to the lifting hatches, an electric awning protects outdoor living.

The outdoor kitchen is a practical and ergonomic setup with all the essentials, including a twin-burner induction cooktop, an 85L fridge and a pantry in a second locker further forward. I like how the van height lowers on the airbags for a customisable kitchen height and to aid entry to the van. A compact stainless-steel barbecue is an option, and it’s located further forward on the floor of the storage hatch. It’s your choice for cooking, and if a slide-out cooker is on your must-have list, it’s available. A practical alternative might be a portable barbecue like a nomadiQ to save about 26kg of weight.

Let's take a look at the versatile interior

A manual double step leads through the rear entry, where it’s an easy flick of switches to raise the roof on four electric corner actuators and level the van on its air suspension system. The roof lifts to a generous 2.05m (6ft 7in) of head height and the vinyl sides have zippered openings to allow as much or as little open air and views as you wish. The entry door is relatively short because of the van’s low-profile body, so it takes some getting used to, especially when exiting the van. I found it best to step down backwards, but owners will sort out the best option.

The ensuite is across the rear of the van. It has separate compartments with canvas enclosures up top for the shower and composting toilet, where the optional washing machine is fixed to the rear wall.

A north–south queen-sized bed slots up front between a passenger-side storage locker and the opposite wall, where a low window affords views. So, without a walk-around setup, access is from the foot of the bed, which most folk will navigate easily enough, and which avoids the issues of an east–west bed.

In the centre section of the living space is a compact cafe lounge with a removable table. Families considering the Expedition will like the provision here for a fold-down bed and the conversion of the diner to a second single bunk. A single induction cooktop is included for the internal kitchen.

Opposite is an uncluttered kitchen bench with access to the outside storage and ample 240V points to run a double-burner induction cooktop and your choice of appliances.

How self-sufficient is the Zone RV Expedition?

Even the Expedition’s basic electronics package is better than the upgraded setup in many Australian brands. Zone now uses Australian-made REDARC Electronics components, which are packaged together by REDARC and shipped to Coolum Beach in Queensland for installation. The standard 720W of roof-mounted solar panels can be upgraded to 1080W for a $1750 premium. Similarly, the 400Ah battery pack becomes up to 800W for a $6400 price increase and 51kg of your carrying capacity.

Significantly, the new Australian made REDARC Manager Alpha 100A can pump in up to 100A of charge from a combination of solar, AC and DC sources. So, there’s ample charge from the tow vehicle if weather conditions aren’t optimum. Combined with a 3000W REDARC inverter, you will have ample power for an air-conditioner, cooking and Starlink.

The other main limiting factor for long-term off-grid camping is water, and you should be covered with 225L of fresh water and a dedicated 75L drinking water tank. A 100L grey tank covers you for those national and council parks that stipulate self-contained RVs, and a SEAFLO pump extracts water from a creek if needed for longer bush camps.

But how does it tow?

As tested, the Expedition’s unloaded weight was 2564kg with options like the barbecue, air-con and washing machine, so it’s not overly lightweight for a 17ft van. However, to be fair, you need to factor in the heavy-duty chassis, big wheels and tyres and a top-end electronics package that all add to weight. The ATM is 3500kg, so the payload is excellent at around 1000kg, and many outback travellers will appreciate that once it’s full of water and essentials for long-distance travel. So, a capable tow vehicle like my LandCruiser 200 Series will be a good match, and I saw no vices during our review.

On the limited dirt roads we travelled, the Cruisemaster suspension was smooth and stable, and the four-wheel electric over hydraulic disc brakes were progressive and did not lock up.

Zone RV customer service

Zone’s warranty document is considered and clearly outlines customer rights under Australian Consumer Law (ACL). The warranty on the chassis is five years and the body is covered for two years. The document refers customers to parts suppliers for redress for items like appliances and suspension. Buyers pay progressive payments throughout the build process to leave a final 20 per cent payment on delivery.

The handover is the best I have seen, with a dedicated camp at Hangar O north of Gympie, Qld. Customers pick up the van here and have plenty of time to set it up with guidance from the trainers. Owners camp for the night and can use all features before hitting the road.

What we thought of the Zone RV Expedition

The Expedition starts at $158,000, which is remarkable value. The review model included options like the barbecue, air-conditioner and washing machine for a revised cost of $164,100. You can build your van on the Zone website, and have it costed out as you go. Current build times currently extend to mid-2025.

This latest model continues Zone RV’s dedication to innovation, practicality and aesthetics. It has succeeded with a steely compact hybrid that looks the part and has all the off-grid capability needed for extended travel. Couples and families looking to go the extra mile will love it.

Measuring up

Pros

• Full composite construction
• High-end suspension and off-grid electronics package
• Loads of storage

Cons

• Six-month wait time
• Low entry door

ZONE RV EXPEDITION RATINGS

VALUE FOR MONEY

Remarkable purchase and resale value

TOWABILITY

Smooth and safe. Needs some weight up front to balance at tare

SUITABILITY FOR INTENDED TOURING

Set up for extended travel into remote areas

BUILD QUALITY

Composite construction and top-shelf components 

LIVEABILITY

A compact van with an emphasis on outdoor living and ample space for storing gear

SELF-SUFFICIENCY

Lots of power and water to keep you off-grid

CUSTOMER CARE

Two-year warranty on the body and components might be a bit light on

INNOVATION

Unique build process will be hard to beat

X-FACTOR

One of the best-looking vans around and fully capable

ZONE RV EXPEDITION SPECS

WEIGHTS AND MEASURES

EXTERNAL

INTERNAL

Zone RV Expedition price from $158,000

OPTIONS FITTED

• External barbecue
• Washing machine
• Air-conditioner
  

Zone RV Expedition price as shown $164,100

MORE INFORMATION

Zone RV

85–91 Quanda Road

Coolum Beach Qld 4573

P: 07 5471 6410

E: reception@zonerv.com.au

THE NEXT STEP

If you want to learn the latest caravan news, find the most innovative new caravans and camping gear or get inspired to plan your next adventure to some of the best destinations and toughest tracks in Australia's great outdoors, subscribe to our weekly newsletter. We promise to send you only the best content.

Related articles:

Zone RV factory tour: Discover what makes these vans so special

Caravan review: Zone RV Sojourn

2018 Best Aussie Vans: Zone RV Summit Series