How they’re made

The best materials, patented breakthrough semi-monocoque design and ingenious patented construction methods

Installation of side sheet on enclosed Aerovault trailer


There are Basically Three Components to an Aerovault: 


Aerovault trailer chassis alone
Side view of enclosed Aerovault trailer with 15" aluminum wheels and 8-ply tires
Extended beams from tongue to rear axle of Aerovault trailer


Each chassis is built on a custom-made jig table to ensure accuracy and perfection. Note that 3” x 3” beam that runs down the center from the tongue hitch to the rear axle? That’s the money shot. With most trailers that beam is only as long as the tongue. That makes for an unstable trailer, which will also break down quickly. By running the beam all the way back to the rear axle, the load between tow vehicle and trailer is evenly distributed across all the wheels and axles. 

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.


Custom Machinery Creates This Masterpiece
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.

Side sheet installation on enclosed Aerovault trailer

Aerovault trailer side sheet being bent using custom built machine "Thumper" to create channel

These critical bends are made with Aerovault’s very own 16’ long, 20 ton press brake (nicknamed “Thumper” by our fans). Accurate, smooth, effortless and without scarring, Thumper makes these channels look easy. 

This Aerovault-built machine is a work of art on its own.

Custom roller with nose sheet for Aerovault trailer

Another custom machine we made curves the 1/8” aluminum sheet for the nose in a way that not only doesn’t weaken the aluminum, it strengthens it. The sheet goes into the roller straight and comes out curved!

Side door of enclosed Aerovault trailer

The beautiful and functional curved front doors of an Aerovault are laser cut prior to the sheet being rounded. They are an integrally formed part of the rounded nose to ensure a perfect fit. 

Construction of Aerovault trailer tailgate

From the chassis to the tailgate frame, all Aerovault components are fabricated using custom jigs to ensure a perfect fit every time. We even weld the chassis using a dedicated welding table to ensure it is perfectly level.


State-Of-The-Art Composites Provide The Perfect Aerodynamic Shape And Reduce Weight

Aerodynamic, Lightweight Roof

Enclosed Aerovault trailer fiberglass roof is one solid piece

Always researching improved methods and materials to build the Aerovault’s perfect aerodynamic shape, we explored the use of composites for the most challenging and important aerodynamic aspect of our trailer, the roof. Pleasantly surprised at today’s materials, the Aerovault MKII’s new composite roof is a masterpiece of contemporary materials and great design.

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).

Aerovault trailer fiberglass fender
black gel coat

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. 

The Aerovault is currently offered with white composite components. White not only provides a striking and clean look but it keeps its cool in the heat of summer. We also offer custom colors, including the Aerovault Black. Note: Colored and metallic gelcoats cost more and metallics take more time to apply correctly so please allow 4-6 weeks for completion. Contact us for options and current pricing.

Aerovault LLC Patent No. 9,796,431   and   Patent No. D.801,229


Aerovaults are produced in their Henderson, NV facility with the Mission to redefine the towing experience through innovative design and quality lightweight materials, building trailers that improve the lives of their owners, the people who build them and the planet.


Took first trip with car and Aerovault last night wow! I could not believe how it tracked with a midsize Merc, suv. Without thinking and following traffic I hit 85 in first 15 min of trip! No Big Rig corrections on interstate. Arrived totally relaxed. For the old v nose and ¾ ton I spent tons on sway control and weight distribution. Parts I don’t need now. My congratulations to you for going where no man has gone before!

Hank, SC

I’ve never seen anything like this trailer before. I was towing it to a race last Thursday and passed this tour bus. I noticed all the tourists had come to my side. They were waving and giving me the thumbs up sign. I thought they must really like my car and then I realized they can’t see my car… they love my Aerovault!

Pat, NV

Awesome, Awesome, Awesome! With my previous trailer I had to tow at 65 mph or less or the gearing on my truck would kick down, killing my mileage. With my Aerovault I can now tow faster and still get 35% better fuel mileage than with my other trailer or I can go the same 65 mph and get 56% better fuel mileage. The whole time not even noticing the Aerovault is back there. Good design and engineering really work. My dad always told me, “Buy it right or buy it twice!”

Fred, AZ – Owner of an MKI