The Build

Every Sahara is built from the ground up.

We don't buy-in modular shells or outsource the hard parts. Every van is welded, wired and fitted out by the team that signs off at handover — custom to the customer, from the first cut of steel to the final road test.

Chassis & Running Gear

Steel cross-members welded into the chassis with serpentine-bead reinforcement for rigidity, painted in our workshop colours and dressed up with the A-frame, jockey wheel and coupling — the running gear all axles, springs and shocks then bolt onto.

Composite Floor Panels

Composite floor panels laid out flat and bonded edge-to-edge along every seam — a single sealed platform that the chassis carries and the rest of the van is built up off, dust and water tight before the walls go on.

Composite Wall Build-Up

Aluminium uprights and roof rails infilled with closed-cell composite panels — one wall build-up that handles structure, insulation and the inside surface in a single skin, with hatch and window openings cut to spec.

Internal Framing & Joinery

Pine framing fixed back to the walls, then bunks, overhead lockers, benches and storage cubbies rough-fitted in place — the cabinetry takes shape before linings, doors and finishes go on.

Every stage is signed off before it moves to the next — and customisable at any point along the way.

Build Philosophy

What goes into every Sahara.

The components we choose reflect how we expect our vans to be used — hard, and for a very long time.

Chassis

Fully welded, hot-dip galvanised steel. The foundation every other decision is built on.

Suspension

Independent coil with matched dampers. Tuned per model — standard, reinforced, or heavy-duty.

Water & Power

Dual water tanks, high-capacity batteries, solar-ready. Off-grid where it needs to be.

Interior Fit-out

Solid timber cabinetry, stone benchtops, soft-close joinery. Fit-out that ages with the van.

Ready to start?

Spec your Sahara.

Tell us the trips you're planning and the features that matter. We'll come back with a layout, a timeline, and a price.

Get in touch