Beginnings and Inspirations
My journey in the world of automotive design began 41 years ago, specializing in the intricate field of Automotive Design and Development at Dorbyl Automotive. After a fulfilling a 14 year stint, I sought new horizons so ventured into retail design and manufacturing with Franke Kitchen System, one of the world's largest manufacturers of kitchen sinks and appliances. However, my passion for industrial design drew me back, leading to my current role at Profibre, where we create components for buses, heavy industrial mining equipment, rail, caravans, and military vehicles.

The Birth of Stealth Caravans
The transition to designing caravans was a natural evolution for Profibre. Having produced caravan bodies and interiors for another manufacturer for 8 years, we decided to create our own line of caravans. In 2018, we embarked on this ambitious project, resulting in the launch of the Stealth XR6, a road-going caravan, by the end of 2018.

Learning from the Market
The Stealth XR6 aimed to address the common issues in traditional caravans sold in the South African market previously built by CI caravans, such as wood rot and chassis cracking in gravel road versions. We designed and manufactured the first prototype within eight months, but despite its advanced features of rot free body structure and superior running gear, it didn’t achieve the expected sales. The market had shifted towards gravel and off-road caravans, prompting us to adapt or strategy and product offering.

Embracing the Challenge: Developing the Gravel Road Caravan
Initially skeptical about using rubber-ride type suspension for gravel roads, I was determined that our gravel road caravan would be fit for purpose. Our testing began by modifying our existing on-road caravan with more durable tyre’s and securing internal items more robustly.
We tested these modifications on notoriously bad gravel roads in KZN, including the gravel roads between Himeville and Nottingham Road (Lower Lotheni rd) and Underberg to Silver Streams Resort. The tests revealed the importance of tyre pressure reduction to cope with harsh gravel road conditions, leading us to make further adjustments such as replacing conventional rear steadies with drop-down steadies and fitting a rear rock slider to protect the back of the van when exiting drop offs at bridges etc.

Rigorous Testing and aIterations
We continued extensive testing on various gravel roads across Northern Natal, Prince Alfred’s pass in Eastern Cape and district roads in the Sundays River Valley area,. Each test provided invaluable insights. For instance, on one occasion, neglecting to reduce tyre pressure on a notoriously bad 25km gravel road between Addo and Nanaga farm stall traversing the Addo national park resulted in internal damages like a loose fridge and a dislodged microwave. This highlighted the necessity of maintaining lower tyre pressures on gravel roads as we had already done 1000km of gravel roads at that stage without incident.
We also discovered that preventing dust ingress required double compression locks on all doors and fitting a dust suppression scoop on the roof (we subsequently realised that the hatch door and window sealing is so good we no longer need the roof mounted scoop). Mechanical inspections identified some weaknesses in the A-frame, which we addressed before production started on the first salable units. The internal cupboards with recessed doors proved invaluable to withstand the rigors of poorer gravel roads but we realised that sliding doors are not ideal for this application.

Launching the Gravel Road Vans
By 3rd qtr-2019, we launched our first gravel road vans with beefier axles, accompanied by a clear terms of use document emphasising the importance of tyre pressure reduction (to facilitate ease of use every gravel road van is supplied with tyre deflation valves). Alongside this, we developed the Bush Lodge prototype for more extreme environments like Namibia, Botswana and Zimbabwe. This prototype featured a thicker A-frame, additional under step and front rock sliders and changes to the interior cupboards.

Real-World Testing: Botswana and Zimbabwe
Our first test journey through Botswana and Zimbabwe included a mix of on-road and gravel road experiences, testing the Bush Lodge prototype under various conditions. The trip revealed the harsh realities of off-road travel, such as the wear and tear from fine gravel shrapnel, necessitating additional protection measures like long mud flaps on your tow vehicle and a thicker travel blanket. The test route over 5500km of travel mostly reasonable paved roads with some poorer paved sections in Zimbabwe. The main gravel sections where between Stockpoort boarder post and Mahalapye where we experience the fine gravel for the first time. Then the notoriously bad gravel road between Milbizi and Karoi in Zimbabwe along the southern boundary of lake Kariba. The next challenge was the entry and exit roads to Nyamepi camp in Mana pools national Park Zimbabwe. During this entyre trip we experience no major problems as we deflated tyre’s between 1.5 and 1.8 bar on all gravel roads dependent on severity of the road conditions.

The Namibia Expedition and the Sossusvlei Challenge
Our Namibia test run in December 2019 included traversing the Kgalagadi, where we experienced both good and poor sand roads. Despite some challenges, the van performed well, thanks to careful management of tyre pressures and driving speeds. However, nothing could have prepared us for the severe road conditions leading into Sesriem.
The 30-kilometer stretch to Sesriem on the C27 was the ultimate test of endurance for both our caravan and our spirits. The corrugations on this road were relentless, transforming the journey into an ordeal. Mini speed humps formed by the corrugations formed by heavy trucks and busses from the Lodges made it impossible to find a comfortable speed, no matter how slow or fast we drove. We dropped the car tyre pressures to 1.5 bar and the caravan’s to 1 bar, but the punishment was unavoidable.
This 30-kilometer section took nearly two hours to traverse, each moment filled with constant jarring and shaking. Upon arrival at Sossus Oasis, the aftermath was evident. Inside the caravan, the contents of the fridge were all over the inside of the fridge. Containers popped open and lids of jars unscrewed, creating an almighty mess. The pantry revealed cartons of juice and milk softened almost to the point of rupture.
Mechanical inspection showed no major structural damage, but the toll on the interior was evident. One drawer catch had dislodged itself, and the air conditioning had failed, making the remaining journey in the December heat less comfortable. This experience underscored that such severe road conditions were beyond the reasonable capability of our gravel road van, which performed admirably under most gravel road conditions but faced its limits on this unforgiving stretch.

What best describes Gravel Road Conditions

Moderate Condition:
Surface: The gravel surface is generally intact with some loose gravel, but most of the roadbed is firm. There may be minor potholes and ruts, but they are infrequent and shallow.

Driving Experience: Vehicles can travel at a reasonable speed without excessive bouncing or swerving. Occasional slowing down may be necessary to avoid minor imperfections.

Drainage: The road has adequate drainage with few standing water issues after rain.

Poor Condition:
Surface: The gravel surface has wear with large sections of loose or missing gravel. Sporadic Potholes and ruts are present but avoidable. Washboarding (rippled sections) are common but sporadic, making the road uneven.

Driving Experience: Drivers need to reduce speed considerably to navigate the rough surface. The ride is moderately uncomfortable, with some vibrations, there is a higher risk of losing control on loose gravel. These can be travelled with a gravel road van but tyre pressure reduced to 1.2 to 1.5 bar and speed limited to 60 km/h

Drainage: Drainage is often poor, leading to areas of standing water or muddy sections after rainfall.

Extremely Poor Condition:
Surface: The gravel surface is severely degraded, with large sections completely eroded, exposing the underlying dirt or rock. Deep potholes, large ruts, and extensive wash boarding dominate the road and are unavoidable.

Driving Experience: Travel is challenging and slow, with a significant risk of vehicle damage or getting stuck. Drivers must exercise extreme caution, and off-road vehicles may be necessary. These roads should be avoided when using a gravel road caravan.

Drainage: Drainage is inadequate or non-existent, leading to large puddles, mud pits, and possible road washouts after heavy rain.
These definitions provide a clear understanding of what to expect when encountering gravel roads of varying conditions and what to avoid in your gravel road caravan.

Conclusion and Future Directions
After thousands of kilometers of rigorous testing, we confirmed that a caravan with rubber-ride type suspension could handle reasonable gravel road conditions if tyre pressures were properly managed. Severe gravel roads, however, posed significant challenges, leading to inevitable wear and tear. Thus, when planning a trip, it is essential to determine road conditions at the time of travel and avoid poor gravel roads with severe corrugations. It is also advisable to fit tyre pressure and temperature monitors to your caravan wheels.
As a guide to tyre pressures the following would apply to a fully loaded van
Moderate gravel roads 1.5 to 1.8 Bar max speed 80km/h
Poor gravel roads 1.2 to 1.5 Bar max speed 60km/h
Extreme gravel roads avoid if you can if not drop pressure to 1 bar and do not exceed 40km/h
It would also be advisable to purchase a compressor to reinflate tyre’s when back on the hard top
For the more adventurous Stealth has developed a range of products in our overlander series of vans more suited to severe gravel and off-road conditions. We are also in the process of developing add on features for protection from the sand blasting effect of gravel in Namibia and some parts of Botswana.

Reflections
The journey of developing the Stealth Caravans Gravel Road Caravan has been one of learning, adaptation, and relentless pursuit of excellence. Each test, each modification, and each journey has brought us closer to creating a product that embodies the spirit of adventure and resilience. As we continue to innovate, our commitment remains unwavering: to design and develop caravans that are not only fit for purpose but also exceed the expectations of our customers.
So, if you are looking for a well-designed and thoroughly tested gravel roader get down to your nearest Stealth dealer to buy a Stealth X-Country or Bush Lodge that is “comfort that follows you”.
Garry Coady Managing Director, Profibre Products Owner, Stealth Caravan Brand