XCore Construction
built different. built to last.
XCore Construction
At Kokoda, we don’t just build caravans, we build for the road less travelled. For the corrugated tracks, the red dust and the places that test your setup and your patience. That’s why every Kokoda is built using XCore Construction, our exclusive bonded panel system designed in-house for maximum strength, all-season insulation and lasting durability. Because when you’re kilometres from anywhere, your caravan’s structure shouldn’t be a thought. It should just work — silently, solidly, confidently.
what is XCore Construction?
XCore is a frameless, bonded panel construction system that replaces traditional timber or aluminium framing. Instead of building around a frame, we use high-performance composite panels that are vacuum-bonded together to create a fully sealed, self-supporting shell. It’s a smarter, stronger way to build.
We developed XCore to solve the problems we saw with traditional caravan builds:
timber frames
can rot, warp and absorb water
aluminium frames
offer better longevity but still rely on bolts, rivets and joints which are weak points that can loosen over time
Both methods leave structural voids that reduce thermal efficiency and increase weight.
So we built a better way. One that’s fully sealed, more efficient and far more capable in the kind of terrain where Kokodas belong.
Want to know more about how we think about caravan design?
how it benefits you
XCore composite construction allows for greater design flexibility compared to traditional materials like aluminium or steel. Because we manufacture every Kokoda Caravan in-house, we maintain complete control over the build process ensuring precision, consistency and exceptional quality at every stage. We create sleek, modern designs with smooth curves and contours, as well as features like large windows that enhance both the aesthetic appeal and functionality of your caravan.
stronger shell
A monocoque-like structure means fewer joins, more strength, and better performance off-road.
improved insulation
The closed-cell core inside each panel provides excellent thermal and sound insulation keeping you cooler in summer, warmer in winter and quieter inside.
no timber, no rot
Moisture-resistant composite panels remove the risk of wood rot or degradation over time.
sleek, seamless finish
No external bolts or rivets just smooth, modern lines and a more refined aesthetic.
light weight
Without internal framing, we keep your van tough without tipping it over 3.5T.
less maintenance
With fewer joins, no timber, and a highly durable build, your van stays in top condition for longer — meaning less upkeep and more time adventuring.
which is best?
Choosing the right caravan construction method is critical for durability, strength, weight, and long-term reliability. Here’s how Kokoda’s frameless bonded sandwich panel construction compares to traditional Meranti timber frame and Aluminium frame caravans.
designed & built in house.
XCore isn’t something we buy in. It’s a system we designed, refined, and now build ourselves, right here in our Campbellfield factory. That matters. Because when something’s built in-house:
· You control the quality
· You learn faster from the road
· You don’t cut corners and you don’t pass the buck
Every Kokoda is built by people who know why it matters. People who’ve towed, tested and trusted what they’ve built.
frequently asked questions
about construction
Frameless bonded sandwich panels are the best choice for off-road caravans, offering superior strength, reduced maintenance, and better insulation than both timber and aluminium frame caravans.
Bonded sandwich panel construction is lighter, stronger, and requires less maintenance than aluminium-framed caravans, which still use screws and rivets that can loosen over time.
- Timber frames are prone to water damage, rot, and warping.
- Heavier than modern materials, increasing towing weight.
- Weaker in off-road conditions, with frame flexing leading to structural issues.
Yes! Kokoda’s frameless bonded panels are lighter than traditional builds, making towing easier and reducing fuel consumption.
stronger, lighter & built for off-road conditions
why is bonded construction better than screws?
lasting strength
Our frameless bonding process chemically fuses the walls, roof and floor into one seamless structure, eliminating weak points caused by screws and rivets that shift and loosen over time.
This results in a caravan that’s stronger, more rigid and better at absorbing shocks from rough terrain.
- Vibration resistance – Bonded construction absorbs impacts, reducing internal movement and preventing fittings from coming loose.
- Less maintenance – No screws to tighten or check after rough road travel.
- Superior structural integrity – Ensures cabinets, walls and joins stay firmly in place, preventing internal damage.
Yes. Traditional caravans use hundreds of screws and rivets, which can:
- Loosen over time, leading to squeaks, rattles and panel separation.
- Cause leaks or dust ingress as gaps widen with movement.
- Require ongoing maintenance, tightening screws after long trips.
With Kokoda’s bonded structure, none of these are an issue—giving you a caravan that’s engineered to last with minimal upkeep.
Absolutely. Our frameless sandwich panel design creates a fully sealed, dust-resistant and highly insulated structure. This means:
- Loosen over time, leading to squeaks, rattles and panel separation.
- Cause leaks or dust ingress as gaps widen with movement.
- Require ongoing maintenance, tightening screws after long trips.
blog.
why we build the way we do - the Kokoda XCore difference.
At Kokoda, we’re not just building caravans, we’re evolving them.
tough where it matters. soft where it counts.
When you’re hundreds of kilometres from anywhere, your caravan’s construction shouldn’t even cross your mind. That’s why every Kokoda is built with our exclusive XCore bonded panel system sealed, seamless and built to endure. You won’t notice it until it counts: quieter inside, tougher outside, and fully insulated for all-season comfort. With fewer joins, better thermal performance and resistance to dust and water, XCore is how a caravan should be built. We don’t throw around words like “bulletproof” but we build with the kind of confidence that lets you forget the van and focus on the journey.