When repair seems impossible: restoring a Carthago CHIC S-PLUS after a heavy impact

Sometimes we receive motorhomes for which it has already been decided that a repair is too complex or economically unfeasible.

This was the case with this Carthago CHIC S-PLUS I 64 XL QB on an Iveco chassis, manufactured in 2024 and with only 3,000 km on the odometer. This is one of the highest-class models in the Carthago range.

The motorhome had suffered a heavy impact to the rear. After the accident, the insurer deemed the repair too complex and expensive. The owner contacted us after having previously been refused the repair by workshops outside of Bulgaria.

The damage turned out to be much more serious than visible

During the initial inspection, it was clear that the impact had not only affected the rear panel. We began a stage-by-stage disassembly to determine the true scope of the damage.

It gradually became clear that the entire rear section of the motorhome had been shifted forward by about 20 centimeters.

Along with it, the bedroom, wardrobes, and a large part of the interior construction had been displaced. The garage floor was crushed, the rear panel was severely damaged, and the rear side panel and tailgate were deformed.

In such a repair, gaining access to the damaged elements is a challenge in itself. To dismantle the rear panel, it was necessary to disassemble the interior up to and including the bathroom. Only then could all structural connections be reached and the full extent of the damage be established.

It was only then that a number of damages were discovered that were not visible from the outside at all – broken or detached elements in hidden areas and deformations that could not have been identified during the initial visual inspection.

Not only the construction was damaged

The impact damaged various interior elements and equipment. Some of them could be restored, while others had to be replaced with new ones.

The front automatic blind, as well as some of the window blinds, were also damaged.

In the Alde heating system, the impact led to ruptured hoses and an antifreeze leak. After restoring the system, it had to be checked and brought back to a normal working state.

The impact also affected the motorhome's electronic systems. Since the collision was from the rear, the airbags did not deploy, but the diagnostics revealed numerous errors both in the automotive systems of the base Iveco chassis and in the systems of the motorhome itself.

For each of these, the cause had to be determined—whether it was a damaged component, a broken connection, a power supply issue, or a consequence of the impact. Then the problems were fixed and the systems were re-checked.

From disassembly to restoration

After establishing the full scope of the damage, the actual repair began.

The damaged structural elements were restored where technically possible, and the broken parts were replaced.

Then the reverse process began – restoring the construction and gradually reassembling the motorhome.

One of the most important tasks was to restore the correct geometry of the rear section so that the floor, panels, doors, and furniture would return to their exact positions.

With the furniture, there was another challenge – the replaced elements had to match not only physically but also in color, pattern, and finish with the rest of the interior. In a motorhome of this class, such a difference is immediately noticeable.

Gradually, the floor, panels, furniture, blinds, and equipment were returned to their places. All dismantled systems had to be reconnected and checked.

Finally, a complete check of the restored systems and functions of the motorhome was carried out.

About a week of actual work

The actual repair work, disassembly, restoration, and assembly took a total of about one week.

However, the final deadline for the repair also depended on the delivery of some specific parts that had to be ordered and waited for.

In the end, the Carthago CHIC S-PLUS I 64 XL QB was restored and returned to a state where it can continue its journey.

For us, this case was interesting precisely because of the combination of structural damage, interior damage, and problems with various systems. To be carried out with high quality, the repair required not just replacing damaged parts, but understanding how the individual elements of a modern motorhome are connected to each other.

Sometimes, to fix a damaged rear panel, you have to go all the way to the bathroom first. And then put everything back—exactly in its place.