Why We Build the Way We Do – The Kokoda Xcore Difference
At Kokoda, we’re not just building caravans, we’re evolving them.
XCore Construction is more than a buzzword. It’s a smarter, stronger way to build for the kind of travel most people only dream about. Think rugged terrain, remote tracks and off-grid freedom, not bitumen and busy parks. It’s a departure from the old ways of doing things. No timber. No rivets. No compromise.
What is XCore Construction?
Put simply, XCore is Kokoda’s exclusive frameless, bonded composite panel system a monocoque-like shell that’s lightweight, seamless and seriously strong. Traditional builds use timber or aluminium frames. We don’t. Our caravans are constructed from high-performance, vacuum-bonded panels that form a rigid, self-supporting structure. That means no frame, no voids, no weak spots just one cohesive shell that’s built to handle Australia’s toughest conditions. It’s not just tough. It’s smart. These composite panels deliver unmatched thermal insulation, greater resistance to water ingress, warping and fatigue, and a clean, rivet-free finish that looks as good as it performs.
The Power of Purpose-Built Interiors
What’s inside matters too. We don’t just fit cabinetry, we bond it. Every piece of internal furniture becomes part of the structure, enhancing the van’s rigidity and creating a seamless, premium feel. Fewer screws, fewer rattles, more refinement. The result? A van that feels open, considered and rock-solid - because it actually is. Running wiring and plumbing through a sealed composite shell isn’t easy and that’s the point. It forces us to innovate. Instead of punching holes, we’ve developed clever internal facades within the cabinetry. These house the essential services - power, solar, water - while protecting them from damage and keeping storage space intact. It’s clean. It’s clever. And it’s all part of building smarter, not just harder.
Why In-House Manufacturing Matters
A lot of brands outsource their builds. We don’t. Every Kokoda is built from the ground up in our Campbellfield factory. That means total control over quality, over detail, over what goes into your van. Our people work side-by-side, from design through to plumbing, electrical, painting, and final assembly. No middlemen. No miscommunication. If we learn something in the field, we feed it straight back into the next build. That’s the power of vertical integration. It’s also the reason we can stand behind our product with full confidence because every screw, every seal, every panel has been placed by someone who knows exactly what it’s meant to do.
Built for Australia. Built to Last.
The XCore system is designed for real Australian travel. Not just the highways, it’s for the red dust, the creek crossings, the corrugated climbs and coastal winds. It’s strong enough to take a beating. Light enough to keep your rig under 3.5T. Efficient enough to handle extreme temps. And smart enough to integrate water tanks, energy systems, ventilation and airflow into every build. It’s easy to build something for bitumen. We build for beyond.
Built With Strength. Created With Passion. Delivered With Pride.
You’ll see these words hanging in our factory. They’re not just slogans, they’re a code. And the only way we can honour that code is by keeping our builds in-house, with people who care. We know what happens when you outsource. You lose the feedback loop. You lose the pride. You lose the evolution. We’re not here for gimmicks. We’re here to build the strongest, smartest, most capable vans on the market and back them for life.
Explore the Kokoda Range and get to know what XCore can do.
View more about our XCore Construction here.