Solar install and van refit

 

 

21/9/12 – 

We volunteered to help Ken and Liz to put some solar panels on their van and trailer to help them freecamp for a bit longer without using a generator. They’ve got a 2005 VW, which is an ex rental in various shades of blue. The plan is to put 375 watts of panels up, through a Tristar 45 controller, and a Trimetic 2025 battery monitor. At the moment, they know the batteries are flat when the lights go out, which isn’t ideal, so hopefully they’ll have a better idea of how much power is left and be able to protect the batteries a bit better.


Once we had a look at the existing wiring it was pretty clear it needed doing again. The alternator charging is done through a solenoid at the front, using light 8AWG cable and a 10AWG earth return, with no fuses or circuit breakers. The fridge isn’t vented and is running on speaker cable about 6 metres from the battery, so it runs continuously due to the voltage drop. Most of the other wiring was very small gauge, with only three fuses in the van. We decided there was not point in doing much until that was rectified. Luckily I’m not paying!


The first job was replacing the alternator charge wire with 4AWG (+ve and –ve), and fusing both ends with 100 amp fuses. A fuse box was installed, and all circuits fused appropriately, and wire sizes increased. The inverter had a circuit breaker added. We also wired up the battery monitor, which worked well.


Once the wiring was improved, and fuses and circuit breakers included, Liz decided she doesn’t like bending down to use the fridge and could it be moved higher off the ground. And so it began. A full refit. The fridge moved to the other side of the van, and lifted 450mm off the floor. Original cupboards removed and new ones built. And of course, the old fridge might as well be replaced! Typically, it became clear that the fridge door wasn’t going to open in its new position because of the cupboards opposite. So the airconditioner needed to be moved so the corner of the cupboard could be chopped off. Which needed new bench tops of course. So that’s where we’re at right now. 

 

And so it begin again
And so it begin again
I've learned to work a bit tidier this time
I've learned to work a bit tidier this time
The original drivers side kitchen
The original drivers side kitchen
A couple of cupboards removed and a new one being built
A couple of cupboards removed and a new one being built
The new fridge cupboard - higher
The new fridge cupboard - higher
A new vent for the fridge
A new vent for the fridge
New switches / battery monitor in fridge cupboard
New switches / battery monitor in fridge cupboard
Passenger side original kitchen with pesky airconditioner
Passenger side original kitchen with pesky airconditioner
Kitchen looking back
Kitchen looking back

 

The next stage is fitting the fridge and new bench tops. More photos to follow when thats done :)

 

 

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Well, we've been making progress with the van. New cupboards have been built, and the fridge is in and working. One of the solar panels is up on the van roof (the other two are going on the trailer), and it is recharging the battery each day. There aren't many loads on the batteries at the moment, but they should cope well once all three are up and running. There is also a new flooring - stick on vinyl tiles whicha have come up well. 

 

Just got some finishing up to do before we head off. We need to finish off a new sofa and sort out the other solar panels. And then we are done. Finally!

One of the solar panels
One of the solar panels
Slide out pantry in the sink cupboard
Slide out pantry in the sink cupboard
The cupboard being built, with new lighter pine tops
The cupboard being built, with new lighter pine tops
A couple of coats of paint
A couple of coats of paint
The top vent for the fridge
The top vent for the fridge
The fridge about to go in
The fridge about to go in
The fridge in and vented. The fridge is holding sub 4C temperatures
The fridge in and vented. The fridge is holding sub 4C temperatures
The cupboard under the fridge, with another slideout pantry.
The cupboard under the fridge, with another slideout pantry.
The TV is now mounted on the side of the fridge cupboard
The TV is now mounted on the side of the fridge cupboard

The van has satellite TV, and the receiver box is now permanently wired into a cupboard, and an antenna connection point mounted outside, rather than trapsing the cables through the van

Cooktop and new benchtop
Cooktop and new benchtop
Both benchtops have foldable extensions
Both benchtops have foldable extensions
The other one
The other one
They both fold down against the side of the cupboards when not needed
They both fold down against the side of the cupboards when not needed
No more blue floor
No more blue floor
Nearly done
Nearly done
All done
All done
The lower fridge vent which feeds straight to the fan on the fridge condenser
The lower fridge vent which feeds straight to the fan on the fridge condenser

 

The two bench seats are being amended to allow seating across the back of the van. This will make it a bit easier to sit around in the evenings

 

 

The back of the new sofa
The back of the new sofa
The back of the sofa from inside
The back of the sofa from inside

Well, we finally finished the van. It looks quite good. The sofa may well get recovered to all be the same colour, but for now its covered in sheets!  The other two solar panels went on the trailer and connect up using Anderson plugs. Should be set for almost continuous power on the road now. 

Wired the panels together for the trailer
Wired the panels together for the trailer
Fastened to the trailer
Fastened to the trailer
Solar connection next to the trailer connector
Solar connection next to the trailer connector
All plugged in and working
All plugged in and working
New floor and cupboard under fridge
New floor and cupboard under fridge
New slideout under sink
New slideout under sink
The finished fridge cupboard
The finished fridge cupboard

 

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We've since headed off to my uncle's in Brisbane for a week and will be on our way south soon. The details are here.