With the Van Build coming to an end, several important projects need some attention. Today I’ll start working on the battery bank of my solar system. Originally, and that was at the beginning of the van build, I installed two 6V Golf cart batteries. This netted me only ~100Ah at 12V nominal. Sufficient for only the most basic usage. At the time also more than sufficient, with only a minimal number of trips planned.
Overview
The main reason however, was that only 3-4 years ago, Lithium battery technology was hardly existent and very expensive. As I look back now, much has changed. We know now, that charging a Lithium battery at below freezing temperatures, is a big No-No, cell balancing must be part of the setup and many more issues are better understood. The development of low priced BMS’s (Battery Management Systems) has also made the DIY setup a possibility.
After fitting and testing the gray water tank, I do the final installation. I also add a vent pipe, close an unused opening and add a 12V valve to the dump line.
Still have a small piece of window, next to the storage closet that needs to be finished. I’ll install a window frame/sill made from Hard Maple and add a plywood cover around it. Later I will use an automotive tweed to finish it. The corners of the frame are made differently than those of the window at the Murphy Bed , but give a similar result.
I continue the installation of the Webasto Gas Heater by removing the passenger seat and pedestal. The hydraulic car jack that is stored under the seat will be moved to another location. To achieve a good seal between the heater and the floor, I install a separate base plate and seal it with some silicone. Then drill the holes for the heater. Finally the heater is inserted in the holes of the floor and attached with four bolts.
Installed the overflow on the gray water tank. Simply a few PVC connectors with on top a small piece of window screen material, held in place with a clamp.
Next will be the 12V electric valve, A switch at the steering wheel will allow me to open the valve and dump the content of the gray water tank at a dump station.
In the process of finishing up the passenger side of the interior, I need to insulate the walls. Before I do that, I pulled the last wiring through the wall cavities.
The wall insulation consists of rigid Poly-Iso, separated about 0.5 inch from the skin of the vehicle with a few dots of spray foam, with the Poly-Iso pressed into it. This void acts, both as a barrier and a way to drain any condensation, without wetting the insulation.
I fill-in most of the storage boxes in the ‘garage’ of my van. They are all open boxes with inter-locking bottoms, except for the top box, which receives a top lid. This Formica-finished top lid has three functions: as a top lid of course, as an extension of the kitchen countertop and as a worktop placed on a imperfect picnic table.
After previously installing the fuel pump, I continue with the fuel (and power) line between the pump and the location where the heater penetrates the van floor.
For extra security, I use a wireloom around the power wire and use a wider fuel line aorund the tiny Webasto fuel line.
Installation of the fuel pump, Rheostat and wire run.
After unpacking the Webasto Gas Heater, I continue building the upper cabinet, including the Rheostat installation. Another unfinished job, was the removal of the van’s jack, which is located inside the passenger side seat’s pedestal, to make room for the heater. Finally, the fuel pump is installed close to where the fuel line enters the gas tank. I pull part of the power wire, that runs to the batteries, including the wires for the main light switch.
A small box that functions as a stand for my Berkey water purifier. Made out of Walnut and a few strips of Maple, it elevates the Berkey and makes it possible to fill your mug much easier.
I also prefitted the one piece plywood ceiling, which will later be finished either with an automotive fabric or a marine vinyl.
