Built to Endure: The Multi-Layer Camper Body Composite Behind Every Wander Voyager Rig

When you’re hundreds of miles from the nearest paved road, your vehicle is more than transportation—it’s your shelter, your protection, your home base. That’s why at Wander Voyager, we’ve engineered our composite system to match the demands of serious overland travel: rugged, lightweight, thermally efficient, and built to last.

Here’s a closer look at the five-layer composite wall panel that defines Wander Voyager cabins:

1. Exterior Fiberglass (FRP)

The outermost shell of our body is made from high-strength fiberglass—resistant to UV, moisture, and abrasion. It’s designed to handle the harshest environments, from desert sandstorms to freezing alpine rain. Unlike aluminum, fiberglass doesn’t dent or corrode, making it ideal for real-world overland abuse.

2. PET Structural Foam

   Next is a 10mm layer of PET foam core. Made from recycled materials, PET provides exceptional compressive strength without adding weight. It acts as a structural backbone within the panel, giving rigidity and resistance to flexing during rough terrain driving—all while being environmentally friendly and resistant to mold, water, and rot.

3. XPS Insulation Core

   Thermal performance is crucial in both blazing heat and sub-zero nights. That’s why we use a generous 60mm of XPS (extruded polystyrene), a closed-cell insulation with one of the best R-values per inch available. Whether you’re parked under the desert sun or camped on snowy peaks, this layer keeps your interior stable and efficient.

4. Fiberboard Structural Layer

   The internal structure is reinforced with 3.0mm fiberboard, which helps maintain the panel’s integrity and provides a secure base for cabinetry, mounts, or other interior systems. It’s strong, easy to work with, and critical for long-term durability on the inside of the shell.

5. Interior Fiberglass (FRP)

   Finally, the inner wall is finished with a smooth, 1.5mm layer of fiberglass. It’s hygienic, easy to clean, and impervious to moisture—perfect for life on the road where mud, condensation, and rough gear are daily realities.

Reinforced with Wood Stud Framing for Structural Integrity

In addition to the multi-layer composite panel, we’ve embedded strategically placed wood studs within the wall structure to provide enhanced rigidity and mounting strength. While our PET foam and XPS core offer lightweight insulation and impact resistance, wood studs play a vital structural role:

• Secure Mounting Points — Whether you’re installing overhead cabinets, molle panels, or recovery gear mounts, wood studs offer solid anchoring without compromising wall integrity.

• Increased Torsional Strength — When navigating rough terrain or uneven loads, the stud framework reinforces the wall’s resistance to flexing, twisting, or deformation.

• Modularity & Upgradability — Need to add accessories down the line? Stud framing gives you flexibility to retrofit interior components securely.

Our body system is thoughtfully engineered to place wood only where structural reinforcement is needed, allowing us to maintain a strong, reliable frame without adding unnecessary weight. The result is a balanced construction that combines solid mounting support with a lightweight, moisture-resistant core—built for long-term durability in demanding environments.

This hybrid structure delivers the strength of a cabin with the performance of a high-efficiency shell, ready to handle whatever trail you take.

Why XPS?

Extruded Polystyrene (abbreviated XPS) is a common insulation building material used in the construction of homes and commercial buildings. It’s the same material used for foam egg cartons, except that it’s extruded into board form when used as insulation. XPS is used in construction to insulate walls, foundations, and under concrete slabs.

• High Thermal Efficiency

XPS offers one of the highest R-values per inch among rigid insulation materials, helping maintain a stable interior temperature in both hot and cold environments.

• Closed-Cell, Moisture-Resistant Structure

Unlike open-cell materials, XPS doesn’t absorb water—making it ideal for humid, rainy, or high-condensation conditions often encountered on the road.

• Lightweight with Structural Support

Despite its excellent insulation performance, XPS is lightweight and adds minimal mass to the vehicle, helping maintain fuel efficiency and payload flexibility.

• Durable & Long-Lasting

XPS retains its shape, thermal properties, and rigidity over time, ensuring long-term performance in rugged, off-grid conditions.

• Ideal for Overland Conditions

Whether in desert heat or alpine chill, XPS acts as a thermal barrier—reducing energy use, increasing off-grid capability, and enhancing overall comfort.