THE MORELO Chassis Modification

Before any options come into play, the body is given its load-bearing foundation: depending on the vehicle series, subframes and lateral outriggers supplement the standard chassis. They support the floor structure across the full vehicle width, integrate the double floor and modular furniture, and distribute loads from driving operation, stabilizer operation, and payload. Positioning, bolting (hole patterns/spacings), and corrosion protection are carried out in accordance with the manufacturer’s specifications; all work steps are documented.

Rear Lowering
For garages and carrier solutions, the rear end is lowered (depending on vehicle and model). This reduces loading height and creates defined mounting points for bicycle, motorcycle, or car carriers—without losing sight of driving dynamics.

Many options from the > MORELO price list that relate to the chassis are already implemented at Fahrzeugbau MEIER in Altdorf—before the chassis is transferred to Schlüsselfeld. This ensures that air suspension systems, tanks, track-width solutions, wheels, and electrical interfaces are cleanly integrated from the outset.

Why does this make sense? Accessibility & efficiency: Many interfaces are later located “beneath the body” — what is properly integrated now does not need to be laboriously exposed later. Everything from a single source: mechanics, electrics/sensor systems, documentation, and inspection reports are all aligned—one responsible party, one process. Seamless handover to MORELO: the chassis arrives in Schlüsselfeld ready for body installation, allowing work to begin immediately—more plug-and-play, less searching and frustration.

This work is carried out by trained electrical and electronics specialists who think in terms of circuits—not wire colors. With a focus on signal paths, grounding concepts, and EMC (electromagnetic compatibility), what ultimately matters is not the “click” of a connector but the logic behind it. The result is clearly defined interfaces, reliable protection, and a body electrical system that integrates seamlessly with the chassis.

Homologation literally means “conformity”: the manufacturer confirms that the delivered build condition exactly matches the documentation approved by the KBA.

At MORELO, this is based on the existing Stage 1 type approvals of the base vehicle manufacturers (IVECO, Mercedes-Benz) and—depending on the project—on approvals from the chassis manufacturer (Stage 1 or Stage 2). From this, a vehicle-specific specification sheet is created that precisely documents the final build condition of the motorhome (including the modified chassis): engine/transmission variants, possible wheelbases, wheel–tire combinations, permitted track widths, approved towing systems, electrical components and interfaces, among others. Changes to the base vehicles are continuously reviewed and incorporated, keeping the documentation up to date.

For all homologation-relevant add-on components, test and laboratory reports from recognized technical services (e.g. TÜV, DEKRA) are available and assigned to the specification sheet. After review, the KBA grants the type approval (with approval mark, broken down by type/variant/version). On this basis, a CoC (Certificate of Conformity) is issued for each vehicle—an essential prerequisite for smooth registration and complete, traceable vehicle documentation.

The factory-installed wheel spacers are made from high-strength aluminum alloy (e.g. EN AW-7075 / AlZn5.5MgCu), selected for its strength, toughness, and fatigue resistance in commercial-vehicle operation. Spacers, wheel studs, and wheel nuts are designed as a matched system, engineered for the wheel loads encountered in service and the specified tightening torques.

Suitability is demonstrated through a test program conducted by recognized technical services (e.g. TÜV/DEKRA):

• Rotating bending test – simulates adverse lateral forces during cornering; the wheel spacer is tested for fatigue strength under a rotating bending moment in the installed condition.
• Rolling test with slip angle – evaluates behavior under combined wheel load and imbalance in accordance with applicable requirements.
• Seating, hardness, and strength tests of the fastening elements – verify clamp length and preload.

All results are documented with report numbers and assigned to the vehicle’s specification sheet.

For installation control, safety-relevant bolted joints are marked; seating and orientation remain visible until final acceptance, so any loosened fastener would be immediately apparent. The torque wrenches and power tools used are regularly inspected, calibrated, and certified; the corresponding records are on file.

At the end of the production line, quality assurance brings all threads together. For each chassis, a final, structured acceptance is carried out across all relevant areas—including wheelbase and reinforcements, platform and interfaces, electrics and sensors, as well as axle and wheel components. Each item is assessed as OK / not OK / not ordered; any deviations are documented with root cause and corrective action.

Double safety: safety-critical steps receive dual checks (production and QA) and—where applicable—signature lists. If a confirmation is missing, the step is restarted and rechecked. Markings at defined points facilitate traceability on the vehicle.

After production, the technical inspection and adjustment work begins—carried out exclusively by trained specialists. In the service pit, tire pressure, leak tightness, fastenings, and wheel clearance in the wheel housings are checked; safety-relevant bolted joints remain marked so that seating and orientation stay visible until final inspection. In parallel, the manufacturer’s diagnostics establish an electronic baseline (fault memory, live data, initializations). Building on this, a vehicle-specific wheel alignment (toe/camber/caster) is performed based on the actual body weight, driver assistance systems are calibrated (e.g. front camera/distance radar), and air suspension and leveling jacks receive their basic settings—including a defined tilt function for convenient tank draining. A road test of around 30 km then verifies straight-line tracking, steering precision, braking performance (ABS/ESP), noise and vibration behavior, and the interaction of all systems.

Experience gained from service and real-world operation at Caravantechnik MEIER in Burghaslach (just approx. 3 km from MORELO) is systematically analyzed and continuously fed back into all processes—design, quality assurance, work instructions, training, and software versions. This creates a cycle of continuous improvement: details are refined, standards are raised, and solutions become more durable.

MEIER therefore provides MORELO with the best possible foundation to bring the brand promise “WELCOME HOME” to life.