Important to know: Two parties are involved when increasing the permitted weight. On the one hand, AL-KO VT as the chassis manufacturer will explain what is technically possible for the chassis. On the other, the manufacturer of your caravan must approve which weight upgrade the body can handle in everyday use. More information can be found in the section “Necessary documents for a weight upgrade”.

The payload is calculated as the difference between permissible gross weight and unladen weight: Permissible gross weight – unladen weight = payload

As the unladen weight specified in the registration certificate may not always correspond to the actual empty weight, we recommend weighing your caravan beforehand. If your caravan has an AL-KO VT chassis – which is the case with almost all manufacturers today – we can offer you tailored solutions and options to load more weight in your caravan and start your journey without stress. In this guide, you’ll learn which measures are generally available and what really matters.

There are numerous ways to achieve the desired weight upgrade – but not every option is possible for every caravan. The suitable measure depends on the combination of current weight, desired additional payload, and the design of the chassis components of the caravan. Generally, the greater the difference between the current and target permissible gross weight, the more components or chassis parts need to be replaced. Therefore, the costs for various upgrade types can vary considerably, and even within the same upgrade option, costs may differ substantially depending on the starting situation.

To determine which approach will get your caravan to the desired goal, the first step in every enquiry is the Checklist for weight upgrade for AL-KO VT chassis. This is the fundamental requirement for further advice and the basis for all subsequent steps towards an increased gross weight for your caravan.

In this checklist, you fill in essential technical information about your caravan. With this data, our expert team then determines which components of your caravan can already support the desired higher load and which ones will need to be upgraded.

We require the following details from you:

• Caravan manufacturer
• Caravan type / caravan model
• Vehicle identification number
• Chassis drawing number (chassis number)
• Registration and weight data
• Release from the manufacturer (certificate of no objections)
• Technical data for axle, wheel brake, overrun device, towing connection, and tyre size

Why is the checklist so important? AL-KO VT as the chassis manufacturer cannot determine the exact components and their technical details of your caravan solely from the model name. This information is essential for addressing the weight issue and therefore the upgrade of your caravan. The interaction of the components determines the upgrade variant that’s suitable for your individual vehicle.

Document-based weight upgrade

With some caravans, a so-called document-based upgrade is possible. This is an upgrade that takes place only on paper – that is, in the vehicle registration certificate. This change involves no technical modifications to the chassis and is processed exclusively via the caravan manufacturer. The manufacturer simply checks for which maximum total mass your caravan’s chassis is actually designed. They then confirm this via the certificate of no objections and issue the new type plate. Afterwards, you present the caravan to an inspection body such as TÜV or DEKRA for approval, and lastly you have the new permissible gross weight entered in the vehicle documents at the registration office.

Disadvantages: This type of upgrade is only rarely possible and typically results in only a minor increase in weight or payload.

The cost for a document-based upgrade starts at approximately 150 euros, depending on whether a brake calculation is still required by the chassis manufacturer.

Replacing the suspension elements in the axles

A bit of background knowledge on axle suspension: If your caravan is to carry more weight, it’s the axles that bear it first. The axles house the suspension, which consists of rubber suspension cords. There are three suspension cords on each side of every axle. Their lengths and hardness vary depending on caravan type. If too much weight is placed on axles for which they are not designed, the rubber cords deform over time and the trailing arm is misaligned in the axle tube. Visible signs of overloading include worn tyres on the outside, which can ultimately result in a blowout – not a pleasant thought!

To correct or prevent overloading and the resulting damage, we are happy to check if upgrading the suspension cords to a stronger version would be suitable for you.

For this type of weight upgrade, the caravan’s axles are removed, and the rubber cords replaced. Based on the desired weight increase, our experts calculate what length and hardness the new suspension cords must have to bear the increased axle load. Once the new cords are installed, tracking and camber are precisely adjusted. With this upgrade type, a maximum weight increase of up to 200 kg can be achieved.

Depending on the situation and desired weight, it may be necessary to replace chassis components for an upgrade. This could include the complete axle(s), brakes, shock absorbers, overrun device, or frame parts. Which parts of your caravan can already support the desired extra load, and which ones must be replaced, is also determined using the checklist.

In addition to the data from the checklist, additional factors need to be checked for this type of weight upgrade. These include the presence of a GRP floor (glass-fibre reinforced plastic), stabiliser coupling, ATC, manoeuvring system, tyre and wheel capacity, available space in the wheel arch, or 100 km/h approval, as these features also affect the overall interaction of all components. AL-KO VT reserves the right to carry out upgrades exclusively at its own customer centres.

By replacing the appropriate chassis components, the permissible gross weight can be increased by up to 300 kg.

The base price for this upgrade starts at 1,800 euros, but the exact combination of components depends on each individual chassis. Costs may therefore be significantly higher depending on the case.

Replacing the entire chassis

To increase the permissible gross weight of your caravan, it may also be necessary to replace the entire chassis. This applies if replacing individual components is insufficient for a meaningful weight increase. As with replacing chassis components, various equipment features are checked (GRP floor, stabiliser coupling, ATC, manoeuvring system, etc.).

When replacing the chassis, the existing chassis is completely separated from the body and replaced with a new one designed to support the intended load. With this option, up to 500 kg of additional weight can be achieved.

The starting price for a full chassis replacement is 5,800 euros and, here too, costs will depend heavily on individual circumstances.

Overview of the different upgrade types and costs

• Document-based upgrade, possible increase: 100–200 kg, cost: approx. 180 euros
• Replacement of suspension cords, possible increase: 100–200 kg, cost: approx. 500 euros
• Replacement of chassis components, possible increase: 100–200 kg, cost: approx. 1,800 euros
• Replacement of the complete chassis, possible increase: 100–200 kg, cost: approx. 4,800 euros

Necessary documents for a weight upgrade

You now know which upgrade options are generally available. At this stage, you should contact the manufacturer of your caravan to clarify how much extra weight is permitted for your model.

To do so, you must apply for a so-called certificate of no objections. The manufacturer confirms with this document that the caravan body, after the upgrade, is suitable for the new, higher permissible gross weight and may be put on the road. Additionally, in almost all cases, the caravan’s type plate must be replaced – this is also issued by the manufacturer with the new specifications.

These documents are not only required for the upgrade process at AL-KO VT, but they are also mandatory for the final inspection of the upgrade by an authorised test centre (e.g. TÜV or DEKRA). Finally, you must have the new weight specifications entered into the vehicle documents (registration certificate) by the registration authority.

What else to consider when upgrading

Although only the permissible gross weight of your caravan is changed with an upgrade, this affects the entire vehicle combination.

• Towing vehicle: Please check whether your towing vehicle is also rated for the future weight of your caravan.
• Speed restrictions: The increased weight may result in losing your 100 km/h approval if the trailer, after the upgrade, is heavier than the towing vehicle. This would lead to a speed limit of 80 km/h on German motorways. Different regulations apply internationally.
• Driving licence: Check your current driving licence class. If the combination exceeds 3.5 tonnes gross weight after an upgrade, you’ll need at least a BE licence.

How much does a caravan weight upgrade cost? Are there fixed prices?

The cost of a weight upgrade cannot be given as a fixed amount. The reason is that every caravan is unique. The combination of all components in your caravan determines the type of upgrade and its cost – there are no standard prices. This is why the checklist is essential for calculating the upgrade.

Can you upgrade a caravan after purchase?

Yes, it is possible for many models. Here too, the defining factor is the specific starting condition of your vehicle, which we determine through our checklist.

Who performs a weight upgrade?

Caravan weight upgrades are generally carried out by the chassis manufacturer after checking the prerequisites of each individual vehicle. An exception is the so-called document-based upgrade, which requires no technical modifications. This is simply approved by TÜV and entered in the vehicle documents by the registration office.

Where can I upgrade my caravan?

AL-KO VT reserves the right to offer upgrades exclusively in its own customer centres. As a chassis manufacturer, we have holistic expertise and can give professional advice on which tailored solutions may be suitable for the chassis. In addition, we can draw on the full expertise of our development team in case of unforeseen challenges and have access to specialised technical equipment.

How long does the process of upgrading take from enquiry to completion?

The required time is just as individual as the cost question. Depending on which upgrade option is suitable for your required weight, we determine which components must be replaced. The delivery time for these components is a key factor in the overall process beyond our control. We strongly recommend you do not wait until just before your planned holiday to arrange the upgrade. We assure you, however, that we will carry out the process as efficiently as possible.

Can I increase my caravan's permissible gross weight without limits?

No, this is unfortunately not possible, as the body will eventually reach its structural limits. The manufacturer will specify the amount of additional weight approved for your particular model.

Michael Duckek heads the customer centre at the Kötz location and is an expert when it comes to caravan weight upgrades. For this reason, he was a guest on our partner CamperStyle’s podcast. In the episode 'Caravan weight upgrade', Michael helps answer questions about upgrading a caravan. Listen now!