Upgrading Your Caravan’s Weight with AL-KO VT
More Payload for Your Caravan – Safe and Professional
Find out what a weight upgrade means, when it’s worthwhile, and what options AL-KO VT offers for your caravan
For over 25 years, we have been your expert partner as a chassis manufacturer for caravan weight upgrades. We check individually for your caravan which measures are necessary to achieve your desired permissible gross weight. There are numerous options, all explained in detail on our blog. More questions on upgrading your caravan’s weight are answered by Michael Duckek, head of the customer centre in Kötz, on our partner CamperStyle’s podcast. Listen now!
Would you like to find out if your caravan is eligible for a weight upgrade with AL-KO VT? Simply fill in our enquiry form and checklist. We will review your enquiry individually and get back to you very soon.
When is it worthwhile upgrading the weight?
More payload means more flexibility for your camping holiday
A weight upgrade always makes sense if the permissible gross weight of your caravan is no longer sufficient. Additional equipment, more luggage or changed travel habits can quickly use up the available payload. By upgrading the weight, you create extra reserves and can adapt your caravan to your individual requirements.
Typical reasons for a weight upgrade include:
- Retrofitting additional equipment: For example, air conditioning, an awning, solar panel or satellite system increase the vehicle’s weight and reduce the available payload.
- More leisure and holiday luggage: Bicycles, kayaks, surfboards or other camping accessories require extra payload reserves.
- Changed travel habits: More persons, pets or more extensive camping equipment increase the gross weight and make a weight upgrade sensible.
Overview of Weight Upgrade Options
The possible measures depend on your vehicle and the extra weight you require
Not every type of weight upgrade is suitable for every caravan. What matters are the current and desired permissible gross weight as well as the technical specification of axle, braking system, overrun device, frame, tyres and wheels. As a rule of thumb: the greater the weight increase you want, the more extensive the necessary modifications to the chassis may be.
- Documentation-based upgrade:
For this type of upgrade, no technical changes are required to the chassis. The caravan manufacturer checks for which permissible gross weight the existing chassis has already been designed and confirms it with a certificate of no objection. The manufacturer also usually issues a new type plate.
This option is only available for specific vehicles and generally leads to only a minor increase in payload. - Replacing the suspension elements:
For this type of upgrade, the axles are removed and the existing rubber cords are replaced with stronger suspension elements. The length and hardness of the new axle rubbers are calculated based on the desired weight increase. After installation, tracking and camber are set professionally.
- Replacing individual chassis components:
If replacing the suspension elements is not sufficient, additional chassis components can be adapted. These may include the axles, brakes, shock absorbers, overrun device or frame parts. Which components are already rated for the higher load and which need replacement is checked using the vehicle's technical data.
Upgrading via selected chassis components allows an increase in the permissible gross weight of up to 300 kilograms. - Replacing the entire chassis:
If replacing individual components does not allow a sufficient weight increase, the entire chassis can be replaced. In this process, the existing chassis is completely separated from the caravan body and replaced with a new chassis rated for the higher load.
Upgrading by replacing the entire chassis can achieve an increase of up to 500 kilograms.
Important: Depending on the desired gross weight, you may also need to upgrade tyres and wheels. The towing vehicle, driving licence category and any existing 100 km/h approval must also still be suitable for the new weight after the upgrade.
After a successful weight upgrade, the new permissible gross weight must be approved by a recognised inspection organisation (e.g. TÜV or DEKRA) and then entered in the vehicle documents. Depending on the new weight limit, the permissible driving licence category, 100 km/h approval and permissible towing capacity of the towing vehicle may also be affected.
Requirements for Upgrading Your Caravan's Weight
Before each upgrade, we check which options are available for your caravan.
Not every caravan can be upgraded in the same way. The available measures depend on the technical specification of the vehicle and the desired permissible gross weight. That’s why, before any weight upgrade, we check which components are already rated for the higher load and whether technical modifications are required.
The following points are among those taken into account:
- Vehicle data: Manufacturer, model, year of manufacture, and current permissible gross weight.
- Chassis: Technical specification of axle, braking system, overrun device and frame.
- Tyres and wheels: Load capacity and suitability for the desired gross weight.
- Existing additional equipment: For example, manoeuvring system, stabiliser system (ATC), GRP floor or other add-on parts.
- Space conditions: Adequate clearance in the wheel arch and technical feasibility of the planned weight upgrade.
Only after this technical check can we identify which weight upgrade options are suitable for your caravan and which modifications may be required.
How the upgrade process works for your caravan
Step-by-step to the right weight upgrade
To ensure the weight upgrade is perfectly matched to your caravan, we support you from the initial check to the successful entry in your vehicle documents.
- Fill in the checklist:
Complete our checklist with your caravan's technical details and send it to our service team. - Technical check:
Our experts review which weight upgrade options are available for your caravan and then prepare an individual quotation for you. - Approval from the vehicle manufacturer:
You then apply for approval for the planned upgrade from the manufacturer of your caravan. The manufacturer issues the required certificate of no objection as well as a new type plate. - Place your order:
Once all documentation is complete, you commission AL-KO VT to carry out the weight upgrade. - Arrange an appointment:
We order the required components and arrange an appointment with you at our customer centre. - Professional implementation:
Our service technicians carry out all necessary modifications at our customer centre in Kötz or another AL-KO VT customer centre. - Technical inspection:
After completion, your caravan is inspected and approved by a recognised inspection body such as TÜV or DEKRA. - Entry in vehicle documents:
Finally, you have the new permissible gross weight entered in your vehicle documents at the relevant registration authority. - More payload for your next holiday:
Once the new entry is made, you can use your caravan with the upgraded permissible gross weight and benefit from the extra payload reserves.
Cost of a Weight Upgrade
Every weight upgrade is as individual as your caravan. Therefore, as a chassis manufacturer, we cannot make any statements regarding options or costs based only on the caravan model—we need you to provide the completed checklist as the basis for our work. With this information, we can determine which individual components with which technical features your trailer is made of. We will then provide you with a tailored quotation. As a guide: costs for the simplest type of upgrade (replacing suspension elements) start from around €1,800. The base price for the most extensive weight increase (replacing the entire chassis) is €5,800. Depending on which components need to be replaced or installed, each upgrade option may incur additional costs beyond the base price.
Interested? Send your enquiry here!
Would you like more freedom and wish to have your caravan upgraded at AL-KO VT? No problem! Simply fill out the enquiry form and the checklist using the link provided. We will assess your enquiry individually and get back to you shortly.
If you have any questions, our service team at the customer centres will be happy to help!
Legal Information
After a successful weight upgrade, the new permissible gross weight must be approved by a recognised inspection organisation (e.g. TÜV or DEKRA) and then entered in the vehicle documents. Depending on the upgrade, the driving licence category, the towing capacity of the towing vehicle and the 100 km/h approval may also be affected.
