Caravan Dent Repair & Paint Restoration Systems

Panels on caravans, motorhomes and trailers can be restored to their original condition, quickly and cost-effectively. Patented repair technology

Over two decades ago, HBC System developed and patented an innovative technique for repairing dents and scratches on caravans and mobile homes. Since then, we have consistently improved and perfected the process for repairing caravans.

In the following sections, we will explain more about panel types, how to assess damage correctly, our repair tools, and the repair process. We will also provide templates for comparing and estimating the cost and savings of repairing a caravan panel versus replacing it.

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Technical structure

Most caravans, motorhomes or trailers feature panels made from a sandwich design with a layer of hard plastic or wood as the innermost layer, an insulating foam panel in the middle and a textured aluminum plate as the outer layer.

Aluminum panels with structure?

The primary task of the structure is to make the aluminum sheet more resistant to shocks and to compensate for minor irregularities.

The different structure types

There are currently 4 common types of structures on the market. Each structure has their own properties and must be processed accordingly and requires the use of different tools.

smooth panel

micro structure

normal structure

macro structure

In scope - caravan dent repairs

Out of scope - caravan repairs

German article on the HBC Caravan Dent System in Europe's leading caravan magazine CARAVANING

Read More

Caravan Dent Repair System


Caravan Spot Repair System



Caravan dent repair or a full panel replacement?

Example is based on a typical 8 cm dent on a 5 meter long partially painted caravan.

The prices and hourly rates are estimated net prices based on European market analysis.

Labor costs est.
158 EUR Per Hour - Painting
125 EUR Per Hour - Workshop

Caravan Panel Replacement

Cost Estimate

Repair time30 Hrs.
Wages Total3.750 EUR
Aluminum Panel590 EUR
Window + sealing strips420 EUR
Metal glue85 EUR
Rubber/window profile140 EUR
Sealing material120 EUR
Materials est.40 EUR
Disposal old parts190 EUR

Total 5.335 EUR

Caravan Panel Repair

Cost Estimate

Repair time (4 Hrs.)500 EUR
Painting time (3 Hrs.)474 EUR
Removal, add. paint work (1 Hr.)125 EUR
Dismantle time (1 Hr.)125 EUR
Wages Total1.224 EUR
HBC Repair Materials140 EUR
Paint Materials170 EUR

Total 1.534 EUR

Cost analysis


when performing a caravan dent repair as opposed to a full panel replacement.

Before, during repair and after steps of restoration of caravan dent

How the dent repair system works

With the specialist repair process an exact copy of the surface design or pattern is created from the undamaged part of the panel using the patented vacuum tool, templates, and mouldmaker. The mould is then transferred to the damaged area where the special E-Filler is injected, leaving a surface structure that corresponds exactly to the original panel. After the material hardens the borders are sanded and the whole repair area is powder blasted using a specialist granulate E-Powder. The repair area can then be primed and painted.

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Caravan Dent Repair System

Caravan Dent Repair System

With the HBC Caravan Repair System for the first time panels on caravans, motorhomes and trailers can be restored to their original condition, quickly and cost-effectively. HBC system has successfully designed & developed a specialist repair system which has been rigorously tested and now features a world-wide patent. Traditionally damaged panels (normally the whole side of the vehicle), would have to be replaced which is hugely expensive and very time consuming for the insurer, repairer and owner. Now specially designed vacuum equipment, templates and unique mouldmaker provide a perfect match to original smooth or contoured surfaces. This system is capable of repairing major damage on aluminium panels.
Caravan Spot Repair System

Caravan Spot Repair System

Easy-to-use spot repair paint system for repairing paint damage on caravans, motor-homes and trailers. Complete system that features 15 base colors and specialist color mix, match formulation system using bespoke software. The foundation of the system is 15 base colors, which can be mixed together with the easy to use software (access code and download link is included with the system). When the color software is installed on your pc you are ready to start. Simple and easy!
All-In-One Caravan Repair Trolleys

All-In-One Caravan Repair Trolleys

The ultimate high-end Caravan Repair installation from HBC system. These all-in-one trolleys contain everything a caravan specialist need to successfully repair caravans or mobile-homes. A dent in a caravan wall, cracked bumper, scratched caravan windows or a foul odor in the caravan; this all-in-one caravan trolley offers you a solution for every problem. It is a must for every workplace that requires efficiency, flexibility and mobility.