RV Learning

Comparing Travel Trailer Aluminum

Q: What makes Bowlus aluminum the best in the industry?

The Bowlus is constructed using 2024 T3 "Alclad" aluminum . This is a true aircraft-grade alloy specifically chosen for its exceptional strength-to-weight ratio. While other aluminum trailers use much softer alloys, our choice of 2024 T3 is the secret behind the Bowlus's legendary durability and lightweight performance.

In this video, we dive into why Bowlus uses 2024 alclad aluminum—the same material found in aircraft construction—making it the best choice for strength and durability.

Unlike other aluminum travel trailers that use softer aluminum sheets with a protective clear coat, Bowlus owners don’t have to worry about moisture damage or corrosion. The 2024 alclad aluminum exterior of a Bowlus can be polished over and over, and is far more resistant to impacts, such as hail, compared to softer aluminum trailers that often need rock guards. Watch a live demo showing just how much stronger Bowlus aluminum is compared to other travel trailer materials!

Join Geneva Long, CEO of Bowlus, as she explains the different types of aluminum used on travel trailers and why it matters to camping performance.

FAQs

The Bowlus is constructed using 2024 T3 “Alclad” aluminum. This is a true aircraft-grade alloy specifically chosen for its exceptional strength-to-weight ratio. While other aluminum trailers use much softer alloys, our choice of 2024 T3 is the secret behind the Bowlus’s legendary durability and lightweight performance.

The difference is structural. Other manufacturers use softer aluminum sheets that require a clear coat for protection. This poses several long-term issues:
Corrosion (Filiform): On other trailers, moisture can get trapped under the clear coat, leading to filiform corrosion between the paint and the metal. Because Bowlus uses aircraft-grade aluminum without a clear coat, our exterior can be polished again and again, eliminating this risk.
Impact Resistance: Softer aluminum is highly susceptible to hail damage and road debris. This is why you often see “rock guards” on the front of other trailers. A Bowlus, made from the same material as an aircraft wing, can withstand considerable impact without the need for bulky guards.

The difference in alloy composition is easily felt. In a side-by-side comparison of equal thicknesses:
Standard RV Aluminum: Can be easily bent or even folded in half by hand because the alloy is designed for malleability rather than structural tension.
Bowlus 2024 Aluminum: Remains incredibly sturdy and resists permanent deformation. It bears tension and compression loads, which is essential for our monocoque design.

“Alclad” refers to a process where the high-strength 2024 core is bonded to a thin layer of pure aluminum. This provides the best of both worlds: the immense structural strength of the 2024 alloy and the superior corrosion resistance of pure aluminum. It allows the Bowlus to maintain its mirror-polished shine for generations.

The aluminum skin is only part of the story. We use aircraft-grade rivets and a one-inch rivet spacing—a standard used in aerospace to ensure the shell is both aerodynamic and incredibly strong. This creates a “space frame” effect where the skin and the frame work together as a single, rigid unit.

Using high-strength, lightweight aluminum allows us to keep the Gross Vehicle Weight Rating (GVWR) between 3,500 and 4,000 lbs. This leads to better fuel economy, increased range for electric vehicles, and a much safer towing experience with less strain on your tow vehicle’s brakes and engine.

Video Transcript

Today, we’re going to talk all about aluminum and why the Bowlus aircraft grade 2024 aluminum is the best in the industry. Let’s get started, so Bowlus uses 2024 all clad aluminum, which is the best alloy for applications requiring that high strength to weight ratio. Now we have lots of other videos that talk about our monocoque design, but that’s huge reason why we use the type of aluminum we do as well as the importance of having a lightweight travel trailer and the type of camping performance that gives you. All other aluminum travel trailer manufacturers use much softer aluminum sheets and then they put a clear coat on the sheets for additional protection.

Now this type of aluminum poses a few problems: So first, moisture can still get under that clear coat and create a filiform between the paint and the aluminum. Because Bowlus is made from true aircraft grade aluminum Bowlus owners don’t have to worry about that type of corrosion because that exterior skin can be polished over again and again. Other travel trailers also need to worry about hail damage because of that softer aluminum, and you’ll also see things like rock guards usually on the front of other aluminum travel trailers and again that’s because they’re using a softer type of aluminum whereas Bowlus uses aircraft grade 2024 aluminum and so that can with withstand considerable impact. Think – it’s the same material that aircrafts are made of so a very different level and simply put that’s the secret behind Bowlus’ strength is that aircraft grade design and of course, the aircraft grade rivets as well.

If you want to learn even more about this, please go check out my how Bowlus is made video and also my Rivets Video. Now I’m going to go inside the Bowlus and give you a demo between the type of aluminum we use and the type of aluminum other travel trailers use. Okay, so I’ve explained the differences to you between aircraft grade aluminum and the type of aluminum other travel trailers use, but let’s do a little demo. So here I have aircraft grade aluminum and here I have the type of aluminum other travel trailers are made from. Now I may look strong, but I am not that strong, so please don’t be fooled.

So first of all we have the Bowlus aluminum and I’m going to bend it as hard as I can and you can notice you can get a little bit of bend, but that it’s really quite sturdy and that’s again aircraft grade because of the difference it’s made. Now I’m going to pick up the other piece of aluminum I have, both are the same thicknesses, but again that type of alloy that’s used is different and I’ll just show you how easy it is for me to completely bend that in half so we have you know the difference between the Bowlus aluminum and the other RV manufacturers’ other aluminum RV manufacturers type of aluminum again I’ll just try and bend it you maybe get a little bend, but you can’t keep that bend, whereas basically I can fold this one in half and I’m sure we can find someone much stronger to demo this effect even more. If you have any questions, feel free to leave them in the comments, or feel free to contact our sales team at sales@bowlus.com or bowlus.com.

Geneva Long

Founder & CEO

Geneva Long has redefined the RV landscape since 2011, establishing the ultra-luxury travel trailer category. Drawing from her passion for adventure, she leads with a vision for user-centric design. Geneva ensures that every Bowlus delivers supreme comfort and innovative performance, built with a level of craftsmanship designed to last for generations.