RV maker Cortes Campers recently announced a limited production run of their new Cortes 18 model, which replaces the traditional metal frame with one made of composite. According to the company’s website, replacing a traditional steel chassis with our new patented advanced composite materials, such as fiberglass or carbon fiber, can result in significant weight savings and enhanced performance.
The Unique Building Process of the Cortes 18
Using fiberglass makes the Cortes 18 chassis approximately 68 percent lighter. Further, the carbon fiber option achieves an even greater weight reduction — around 80 percent.
The composite materials also result in superior durability, with the benefit of being corrosion-resistant. The lighter weight can enable less-capable vehicles to tow the diminutive Cortes 18 and the lack of corrosion implies a longer life span for the trailer. Other unique aspects of the model include the fat that the holding tanks are actually molded into the camper itself. The company has applied for a patent on the build process, referred to as monocoque construction.
The idea is that the body and frame form a single structural unit, eliminating the need for a separate frame and making the entire structure stronger. Interestingly, this evokes a process similar to that of many exotic vehicles and airplanes, which undergo a similar build.
This Cortes 18 model — the 18BB — features all the usual things found in a fully equipped travel trailer, including toilet, shower, and a full kitchen. The dry weight of the trailer is 1,885 pounds which is remarkably light.
The exterior is molded fiberglass utilizing vacuum infusion. The company first sprays gelcoat, then adds all the dry fiberglass and core. After that is complete, they inject resin under vacuum pressure, which vacuum-infuses and cures in one process. The process is commonly known as “vacuum infusion”. Many others use what’s called a chopper gun to shred up fiberglass which is applied by hand to the mold. That results in inconsistencies and also a great deal of labor cost. The process Cortes uses is less expensive and more precise.
About Cortes Campers
Cortes is a subsidiary of U.S. Lighting Group which builds a variety of products including products or the RV industry.
“When we started this company, we said we were going to build campers the same way they build airplanes, except with 21st Century materials,” U.S. Lighting Group CEO Paul Spivak said after touring various RV manufacturers.
The company only plans to build 100 of the new models which are available now through the company’s dealer network.
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