IVECO Daily Expedition Project

IVECO Daily Expedition Build

This build was based around a brand new IVECO Daily 4x4 with a 7.5t GVW which made a large and comfortable habitation box possible.

The brief was for a 'softroad' camper, well suited to gravel tracks and light offroad in the summer and able to navigate the alps in the winter, the modern IVECO being a perfect candidate for this. As such we designed a rail on rail subframe that would be best suited for the task and added a range of accessories to increase the utility of the vehicle.

Brand New Truck!

The very start of the project, a brand new IVECO Daily arrives in our yard, fitted out from factory with 4 wheel drive, bash guards and an in cab diesel heater.

Torsion Test

Offroad performance, driving characteristics and the protection of the habitation box are crucial to us, so one of the first jobs was a weighted torsion test where measurements were taken to determine the flexibility of the chassis and to inform the design of an optimised subframe.

CAD Design

The design stage came next, a model of the vehicle was first built then we worked with the customer to develop a design to their requirements.

A range of custom accessories were developed for this vehicle, toolboxes, brush bars, tow point etc.

By building the model in CAD, it makes it much easier to make design decisions and it always helps visualising the space you are going to have inside.

Subframe Optimisation

The subframe is the heart of the build and in this case we designed a sprung rail on rail subframe to suit the light offroad use.

This connects to the chassis rigidly over the rear axle and has progressive spring mounting to allow sufficient movement of the chassis without affecting the box.

Using FEA simulation we optimised the weight of the subframe with a series of cut-outs which kept the weight to just 240kg.

Torsion Test Verification

When the subframe arrived we test fitted it and redid the torsion test to verify all was working as intended.

Passthrough Work

As a passthrough was required the rear of the cab was cut out and a frame welded in to strengthen the panel.

Box Building

The box build starts, all the panels are CNC cut so are ready to be bonded together and we can be confident that all the apertures are in their exact position.

Passthrough Frame

The box side passthrough frame is bonded to the front panel ready to take the accordion seal.

Roof Installation

The roof goes on!

Outbound Windows

With all the panels in place the Outbound windows and doors are bonded in and the edge cappings are adhered on.

Subframe Prep

The subframe is prepped to have the box bolted to it. A layer of rubber stops it from sliding around and ensures the correct preload on the GRP bolts.

It's coming together!

The box and the subframe attached together.

Some careful reversing!

The box and subframe are then carefully married up to the chassis.

Box on

With the main components together the accessories can then be put on for the final time.

Tow Point

The custom pivoting tow point we designed for this build. It pivots up to provide a greater departure angle when not in use.

We also built in two heavy duty recovery points attached directly to the chassis.

Finished Build!

With a coat of matching paint the build is complete and looking great.

Click on for a showcase of the finished project.

Folded Steps

We used a neat set of concertina steps that are stored under the door.

Extended Steps

With adjustable height and individually adjustable legs, they are suited for any terrain.

Views for days!

The large Outbound windows let in lots of light, the panorama of the Yorkshire peaks here was particularly impressive.

Tow Point

Tow point in it's raised position.

Rail on Rail Subframe

The forward spring mount of the subframe allows for the most movement.

Roof Rack

A custom roof rack was attached to hard mounts we welded into the structure of the cab.

CTIS & SLS

This vehicle was fitted with both a Central Tyre Inflation System (CTIS) and a hydraulic Self Levelling System (SLS). The main units for both were neatly positioned in the forward toolbox.