Chris Michel, owner of the Sunseeker Caravans and Vision RV brands on
the Queensland Sunshine Coast, is passionate about modernising the Australian caravan industry. We met in

Ballarat at his new Victorian outlet to unveil his latest project, a composite construction couples van, the magically named Merlin. Like the van, Chris likes to pull surprises, and his latest van has a remarkable list of standard features set to attract new buyers.

Rethinking offroad caravans

Sunseeker introduced its first van in
2015 when Chris transitioned from the automotive industry to establish his own brand of caravans. Initially, he partnered with Melbourne builders for the offroad Sunseeker brand and a more budget conscious Marvel version. As the business grew, his passion became designing better vans for Australian conditions. He took to the caravanning lifestyle with glee and seemed to be forever pushing boundaries and testing his latest ideas in as harsh conditions as
he could find. I pity the poor LandCruiser mechanics trying to fix the battered vehicles after many of his trips into the wilds.

Five years ago, he delivered the first hybrid production Vision RV — importing the bodies and fitting them out in his Coolum Beach factory in Queensland. With his experience building around 400 Visions and his knowledge of computer design, he became eager for a new venture, and the stars aligned for him to manufacture the new Sunseekers in a dedicated Brisbane factory.

According to Chris, the industry needs to abandon old-school thinking of relying on a heavy chassis and a veneered lightweight shell for an offroad van. He sees the success of his hybrid Vision models as proof that automotive production design is the future. His direction is a monocoque body working in harmony with the chassis and cabinetry for a sum of great strength and durability. Of course, other builders have recognised this future, but Chris plans to take the integrated design concept to the next level while making the vans affordable and practical.

Built to endure

The manufacturing process begins long before a chassis rolls into the factory. The team explores design ideas and commits them to the computer-aided design program SOLIDWORKS, where a virtual 3D view of all aspects of the van can maximise the best use of the available space and check how furniture and people interact.

The body panels are 28mm from Link Composites using external skins of 1.6mm Italian fibreglass bonded to a central core of closed cell insulating foam. The front and rear walls and the roof are one piece of composite running from the A-frame to the rear bumper, while the floor is a single woven polymer panel covered with durable vinyl for maximum durability.

All CNC-shaped body components bond seamlessly within their slots and are protected by a sturdy J-mould before being secured to the chassis. The ARV 150mm x 50mm (6in x 2in) chassis wedded to a 50mm x 50mm riser, resulting in a robust unit. Twin Pedders shock absorbers are arranged vertically for optimal damping, supporting the tandem box-section trailing arm suspension. The brakes use 12in drums, and the 33in all-terrain tyres mounted on black alloy wheels enhance the van’s adventurous character. Fitout under the chassis looked neat, with plumbing led well out of danger and the water tanks shrouded with shiny checkerplate.

CNC cut lightweight ply furniture is screwed and glued together and to the walls and floor using superior polymer adhesive/ sealants while interlocking slots ensure a tight and accurate fit.

Modern digital switching in caravans involves complex electrical wiring, so it’s essential to do it correctly and provide for servicing later on. To ensure a fault-free installation, the Sunseeker team runs the circuits through ducting in the cabinets and uses custom looms for a fault-free installation.

First impressions

If you check out the Sunseeker and Vision RV websites, you might notice a trend. White and light-coloured vans predominate, which points to a modern caravan trend of black and dark grey vans that can cause Chris to get hot under the collar. He’s been known to point an infrared camera at competitors’ dark vans to demonstrate how hot they can be. I kind of agree, and I think white vans are neat. The Merlin’s lines are clean and well- proportioned, and the graphics add to the appeal. Lower skirts of black Raptor-coated fibreglass bend to modern style demands and are a practical concession for easy repairs from stone damage.

Behind a 4WD-friendly Cruisemaster DO35 hitch is a stoneguard defending twin 9kg gas bottles and an alloy toolbox with jerry can holders on each side. A large window across the front of the van has a cover for travelling and adds to light and ventilation around the bed inside. Back from there is a tunnel boot where an optional well-designed kitchen slides out. Chris might be the master of outdoor cooking because his vans always seem to get it right. From Gympie (NSW) manufacturer, Bushtucker Kitchens, it’s mint looking and complete with fold-out tables, a storage drawer, twin gas burners and a stainless-steel sink.

At the back is a minimalist bar with a single spare, an external shower and an access hatch to the very clever pump and tank selection manifold. Typically, pumps are hidden away and difficult to access and this compartment allows regular cleaning of the filter and the ability to drain tanks independently. The entry door is down the back, with a double step, suitable hand holds and a three-way security door.

Liveability

Chris advises buyers to choose the smallest van that will suit their needs. To his way of thinking, the 20ft 6in (6.25m) Merlin is the perfect long-term travel van for couples, one for the Big Lap where they won’t bump into each other and where they can hunker down if the weather turns sour for a week. He might be right because this Merlin is a foot longer than the average couples van and offers amenities and space without needing a big American truck to tow it.

The layout separates the entry door from the bedroom, which is the most popular design for privacy and practical use of space. The ensuite is to the right of the door, making it easy to access from outside and reducing foot traffic through the van. You have plenty of space, lots of storage, 

shower. The vanity mirror is angled down so you get an almost full-length view of how you look, which is cool if you are planning a big night out.

Owners will like the roomy kitchen
bench with an induction cooktop and a large 34L combination microwave, grill
and convection oven. The cafe dinette
gives decent legroom and expansive views through the new flat glass, double-glazed and tinted windows. Colour choices are conservative grey against white for a fresh and cheery feel, while hidden variable tone LED lighting adds to a laid-back mood. Contemporary touches include hidden cupboard catches, handy charging points and a digital switching system for lights and appliances.

Staying off-grid

The Merlin 20’6 comes with a standard package that makes you independent for a week or so. A 100L grey tank supplements 190L of fresh water, which is plenty if you are near a river or a beach but might mean frugal use of the shower elsewhere.

The solar and battery setup is impressive. On the roof are 880W of panels charging 600A lithium batteries through a combination Projecta Intelli-Grid 180A charger/3000W inverter. So, there is loads of power to run the 224L fridge indefinitely, as well as electrical cooking appliances. The twin 9kg gas supply should run the outdoor barbecue and water heater for a couple of months.

The toilet is a cassette with a composting unit as an option.

How did it tow?

Check out the photos. I felt very regal towing the Merlin 20’6 around the back roads of Ballarat in a Range Rover. It may not be
the most popular outback adventurer, but

I bet it’s among the most luxurious. The
twin turbo 4.4L V8 produces 740Nm of torque through a silky smooth eight-speed automatic gearbox, which provides loads of power to bring the 2650kg along for the ride.

The Merlin 20’6 towed smoothly over dirt roads and at 100km/h on the open road. Its ATM is 3500kg, so most mid-range vehicles should suit it, but larger models like the LandCruiser or Patrol will be optimal. A Range Rover also works well

The bottom line

Sunseeker has changed course with its new range of composite-bodied vans. The first Merlin is a well-designed and spacious couples van suitable for long trips, including rough outback roads. The base price is $129,990. With options like extra fans and a Linex-coated chassis, it’s $134,185, so it’s well- priced in the competitive offroad sector.

RATINGS

VALUE FOR MONEY

Well-priced in its category

TOWABILITY

Sensible 3500kg ATM and tows smoothly

SUITABILITY FOR INTENDED TOURING
A van for couples on long trips or extended stays in national parks

BUILD QUALITY

Intelligent engineering and great attention to detail

LIVEABILITY

Space for two to move and enjoy the van

SELF SUFFICIENCY

Sensible off-grid power and 190L of freshwater storage

CUSTOMER CARE

Seven-year warranty (two years factory plus five-year AWN extended)

INNOVATION

Sunseeker keeps design contemporary and the new monocoque construction is a positive

X-FACTOR

Conservative looks but it packs a punch