How they’re made
The best materials, patented breakthrough semi-monocoque design and ingenious patented construction methods
1. the chassis 2. the sides 3. the roof
So why aren’t other trailers made this way? Cost. There’s more material involved and a LOT more labor to do it the right way. Other manufacturers know you can’t see how they’ve cut this pretty important corner.
Let’s examine the special methods we use to create the main portion of an Aerovault.
The Self-Supporting Sides
What may at first appear to be the most basic part of an Aerovault is actually the most critical and most difficult component to make. The sides of an Aerovault trailer start as 14’ long flat sheets of 1/8” thick 6061 aircraft/marine grade aluminum. An indentation is then “pressed” into the sides to give it strength. This full length channel or “brake” eliminates the need for any internal framing.
This Aerovault-built machine is a work of art on its own.
Aerodynamic, Lightweight Roof
Using boat hull building techniques, the Aerovault’s fiberglass roof is extremely sturdy (think of a boat crashing through waves), yet lightweight, and still provides the characteristics Aerovaults are known for… namely a clean, frameless interior space.
Roof and body are bonded together using state-of-the-art adhesives designed specifically for bonding aluminum and composites (e.g., as used on the Corvette’s aluminum and composite space frames).
With a clean sheet of paper to design the new Aerovault MKII, Brock couldn’t resist adding some flare (literally) to the Aerovault’s side fenders. Made of strong composite materials, inner wheel wells and outer fenders lock in place on each side of the Aerovault’s aluminum sidewalls, adding additional strength and a great look
Composite pieces get their color from UV-resistant gelcoat when made, not paint applied later. Their finish is an integral component of each piece and free of maintenance.