Boxmanufaktur Composite RV Boxes
FRP & Aluminum Custom Living Habitats for Expedition Vehicles
We manufacture each Boxmanufaktur box individually according to your requirements and suitable for your base vehicle.
Since we manufacture the sandwich panels for our boxes ourselves, we are able to laminate in FRP profiles for flaps and doors or metal frames in the floor. This increases the stability and minimizes the body height. Reinforcements for rear carriers, awnings, floor rails or seat systems with belts can also already be taken into account when pressing the sandwich panels.
For increased torsional rigidity, we recommend that some interior walls and furniture components also be made of sandwich panels.
We plan and manufacture the subframe at the same time, if desired.
Customized underfloor storage boxes made of GRP or stainless steel, roof racks and rear lift solutions round off the overall appearance of the vehicle and create additional storage space.
Boxmanufaktur Box Types
All Boxmanufaktur boxes have been developed for off-road use and are therefore perfectly suited as living habitat for expedition vehicles, 4×4, overland vehicles, and off-road vehicles of all sizes such as e.g.
- Vehicles over 15000 lbs:
Acela Monterra 4x4 & 6x6, Straya 4x4. Ford F450, F550, F600. Steward & Stevenson lmtv, M1086, M1078, Mercedes-Benz NG, SK, Unimog. Fuso. MAN KAT 1. And a lot more. - Vehicles up to 15000 lbs:
Mercedes-Benz Sprinter, Unimog U1300. Ford F350, F450. And a lot more. - Pick-up trucks & 4x4:
Mercedes-Benz G. Ford F150. Toyota Land Cruiser. Land Rover Defender. And a lot more.
Pure-Line Box
The new Boxmanufaktur Pure-Line Box offers you the proven Boxmanufaktur quality with a well-thought-out basic configuration and outrageously short delivery times. To ensure this exceptionally short delivery time, the Pure-Line Box is only available in the specified configuration and with the offered options.
Pure-Line Box Basic Configuration
- Wall strength 57-59 mm
- FRP outer and inner top layers
- Cold-bridge-free floor assembly – 90 mm foam core
- Cold-bridge-free walls and roof – 55 mm foam core
- Integrated aluminum tube reinforcements in the floor for connection to the subframe
- 4 mm thick, surrounding aluminum corner profiles + corner caps - 45° angled
- 2 mm thick, surrounding aluminum corner profiles in the box
- Including a cutout for a door or a hatch
Pure-Line Box Options
- Lenght up to 6200 mm • Width up to 2550 mm • Height up to 2500 mm
- FRP top layer 1 mm or 2mm
- Front or rear slope | 45°
- Ready for underfloor heating
- Aluminum reinforcements in the walls and ceiling for effortless and secure furniture mounting
Individual Box
Our Base Box or Light Box do not meet your requirements? The Individual Box offers you a free choice of top layers, wall thicknesses, shapes, dimensions, etc.
- Custom size & shape
- Wall strength 59 – 61 mm
- Aluminum-reinforced, cold-bridge-free floor assembly 67 – 97 mm
- 1 – 3 mm FRP or aluminum top layer
- Fully wall integrated Boxmanufaktur door
- 4 mm thick, surrounding aluminum corner profiles - 45° angled
- 4 mm thick aluminum corner caps - 45° angled
- 2 mm thick, surrounding aluminum corner profiles in the box
Light Box
Ultra-light FRP top layers and a wall strength starting at 42 mm make the Light Box the first choice for expedition vehicles based on e.g. Mercedes-Benz Sprinter, Ford F350 & F450 or Unimog U 1300.
- Custom size & shape
- Wall strength 42 – 57 mm
- 66 mm aluminum-reinforced, cold-bridge-free floor assembly
- 1 mm FRP top layer outside and inside
- Fully wall integrated Boxmanufaktur door
- 2,5 mm thick, surrounding aluminum corner profiles - 45° angled
- 2,5 mm thick aluminum corner caps - 45° angled
Composite Boxes Options
- Cutouts for windows, hatches & doors
- Installation of KCT, Outbound or Seitz windows & skylights
- Fully wall integrated Boxmanufaktur door & hatches
- Fully wall integrated Boxmanufaktur panorama-hatch
- Front slope, rear slope, alcove/ overcab
- Access to the driver's cab with lockable door
- Integrated low entry | coupé entry
- Interior walls made of FRP sandwich panels
- Reinforcements for furniture assembly
- Reinforcements for rear carrier or airline rails
- Integrated conduits & cable ducts
- Integrated LED lighting for indoor and outdoor
- Integrated floor heating
- And a lot more
Boxmanufaktur Boxes Details
As we all know, the details make all the difference. But what makes the Boxmanufaktur boxes so special? What makes the Boxmanufaktur living habitats different from others?
FRP or Aluminum?
For the construction of your box, we use only individually manufactured sandwich panels from our own production. This allows us almost unlimited possibilities in the implementation of your wishes and personal requirements. From ultra light to extra strong – Different FRP laminates or even 1.2mm aluminum are used depending on the weight and robustness requirements.
Inlays & Reinforcements
Reinforcements can be partially pressed in behind the top layers for easy and secure mounting of e.g. furniture, awnings or airline rails.
Integrated reinforcement frames in the rear wall allow easy attachment of bicycle racks and lightweight spare wheel holders.
Underfloor heating can be optionally integrated in the floor panel.
Ultra rugged
Complex nested corner joints with maximum adhesive surface ensure enormous stability of your Boxmanufaktur booth. The 4 mm thick aluminum profiles and the additional corner caps, also made of 4 mm aluminum, enclose the cabin all around and increase the stability of the cabin again significantly. At the same time, the 45° beveled aluminum profiles protect the cabin e.g. from passing branches or brushwood.
External Options
Access to the driver’s cab
Installation of KCT, Outbound,
Dometic and other windows
& skylights
Cutouts for windows,
hatches & doors
Front slope, rear slope, alcove | cab over
Rear cargo &
spare wheel carrier
Fully wall integrated BoXmanufaktur
hatches
Fully wall integrated BoXmanufaktur
panorama hatch
Roof rails
Custom entry solutions
Fully wall integrated
BoXmanufaktur door
Internal Opitions
Integrated conduits
Integrated LED lights
Integrated reinforcements
for furniture assembly
Reinforcements for e.g. rear carrier, airline/ L-tracks or awnings
Interior walls made of FRP sandwich
panels with optional heating function
Integrated foor heating
Boxmanufaktur Doors & Hatches
Our doors and hatches are made of the same material as the composite boxes and are fully wall integrated during production of our composite sandwich panels. The doors and hatches thus have the same insulation value as the walls and, thanks to the identical surface, blend in perfectly with the cabin design. The 3-point locking system with lever handle set and piano hinge made of stainless steel round off the first-class workmanship and close the doors and hatches securely and tightly.
Perfect Connection
For secure mounting of the box on the sub frame, the cold-bridge-free Boxmanufaktur floor assembly is equipped with integrated aluminum profiles. Alternatively, the sub frame can also be integrated directly into the floor assembly.
Options for Boxes
Choose from a wide range of additional options.
FRP Interior Walls Sub Floors & Furniture Components
We optionally equip your box with intermediate floors and interior walls made of FRP sandwich panels. These not only provide additional stiffening of the box, but are also ideal for separating the bathroom & shower from the living area due to their moisture resistance. The construction of a double floor for the center of gravity-optimized installation of e.g. water tanks or heavy technology is also possible. Very popular is also a garage partition made of FRP sandwich panels to the living area, e.g. with integrated round seating group, dinette or as a platform for your bed.
Floor
Wall &
Bed Box Heating
Our water-based underfloor heating, integrated into the floor structure, ensures even and comfortable warmth throughout the entire interior. It provides comfort on cold days and creates a pleasant living environment.
For added convenience, optional heating loops can be integrated into the bathroom or shower wall, as well as the bed base, to prevent moisture buildup under the mattress. These well-designed solutions turn your vehicle into a true haven of comfort, no matter the outside temperature.
Windows & Skylights
Tempered glass and acrylic windows for your expedition vehicle
For your Boxmanufaktur composite RV box, we use high-quality double-glazed windows and skylights from KCT, Outbound, and other manufacturers. For our weight-optimized boxes, we also offer acrylic windows from Dometic.
Prefer to install the windows yourself? No worries. We will precisely cut the required openings in the box walls to your specifications and provide the desired windows, roof hatches, and access panels along with your order.
KCT Windows & Skylights
- Tempered glass
- PVC/ steel frame
Outbound Windows & Skylights
- Tempered glass
- FRP frame
Dometic Seitz Windows
- Acrylic glass
- Polyurethane frame
Custom Made
Entry Solutions
As diverse as our composite boxes are, so are our customized entry solutions.
Our offerings include, among other things, step ladders, various combinations of platforms and ladders, as well as electrically folding and retractable stairs or box stairs.
The low-entry or coupe entry provides a lower entry edge by incorporating additional steps inside the box. This typically allows access to the living habitat without the need to attach or extend a platform or ladder.
A particularly practical and elegant solution is our integrated ladder, which is space-savingly built into the custom-designed subframe we developed. This solution combines maximum functionality with appealing design while providing a comfortable and safe entry.
Roof Rails
Roof Racks
& Spare Wheel Carriers
Our aluminum roof railing not only provides reliable protection for your expedition vehicle but also stands out with its sleek design.
Reinforced with hand-welded aluminum corner caps, it protects the box, roof edges, as well as installed solar panels and other sensitive components from branches and obstacles.
Our custom-made roof racks offer the perfect solution for any adventure. Whether made from durable steel or lightweight aluminum, we design and manufacture each roof rack individually to fit your vehicle and intended use.
From securely storing your gear to increasing load capacity, our roof racks represent the highest quality and reliability on any terrain.
For optimum load distribution when mounting spare wheel carriers or bicycle racks on the rear wall of your box, we integrate a reinforcing aluminum frame into the rear wall without cold bridges.
We manufacture the suitable spare wheel carrier individually according to your requirements.
Subframe
The foundation for your composite box
All boxes require a customized subframe to decouple the torsion forces of the truck frame and to avoid damages to the living habitat.
In most cases, the frame of a truck is designed to be able to twist, our subframe is made of rigid steel beams, with cross members in the front and rear. The subframe is mounted with feather springs and bolts to the truck chassis.
Additional fixed brackets in the rear and “guide fingers” in the front, make sure the box can safely lift off and return on the truck frame.
We believe that this is the best compromise for on road driving safety and off-road performance.
Some chassis require different solutions like 4-point/diamond shape subframes – we can also offer custom solutions for those chassis
- Feather spring
- Polymeric support
- Three-point support
- Four-point support
- Rhombic support
- Central tube frame
Box installation & interlock test
Assembling the box on the base vehicle
Your Boxmanufaktur box is ready and will now be mounted on the base vehicle. Before we hand over the vehicle to you and you can start building your expedition vehicle, we carry out a final interlocking test to ensure that everything fits and the subframe sufficiently decouples the box from the chassis.
Equipment & Technique
From the empty box to the ready-to-travel expedition vehicle
We turn your box and your base vehicle into an expedition vehicle ready to travel – individual, self-sufficient, safe.
