Starting at the Top: The Roof
Topside
So many steps and so much analysis paralysis reasoning through the best approach and sequence. The goal is to mount three small 100w panels and two large 450w panels among the fan vent, skylight exit, and air conditioner with as little air resistance as possible and everything securely forever in its place too. 1200w of solar power flowing in and feeding the two 12v batteries wired in series, making a 24v battery system.
Mounting Rail for the Awning.
Placing the Pads
Machined Aluminum "Pads" with tapped holes
Painted. Glued. Ready to receive the rack.
Painting Rack in the back 40 of the yard.
Powdercoated Aluminum
Rack & Awning
Brackets Custom Machined & Calculated for Slipstream
Skylight Party Lounge with Inside View of the Rack Frame
Deck for the Skylight Party Lounge!
Custom, John-made, rack for panels & slipstream
Staging the three 100 watt panel around the party deck.
Ceiling Work, The Scary Stuff Done with Confidence. MaxxFan & Nomadic X3 24v A/C
Measuring every time you think of measuring, then measuring again in order to cut and commit with confidence. The fear of a wrong move in the 2.5" walls and ceilings keeps even the most peaceful soul awake at night. Thanks for Lonnie Wominack for the support, emotional and mechanical for the installation. The only snag was with the Nomadic A/C. John had to machine a plate to adapt the cover to mount. It may be because they are designed for vans, but the vents did not line up. Using a sheet of 14ga aluminum, he sheered it to size and milled the inside to make it fit.
Nomadic Fan Schematic
Traced from VanLife's Template. Drill out corners from the inside with a Whole Saw.
Using the Whole Saw-ed holes, a Circular Saw cut through the 2.5" insulated ceiling to complete the square.
& now for the MaxxFan...
MaxxFan Hole Commitment!
Clean Cut
Frame inserted Perfectly
Nomatic A/C requiring a specially machined adaptor plate so the vents aligned
Framing it Out 80-20 for Miles
80-20 Ordered to Size after Hours of Planning
Assembling the frame for the Pantry Drawers
30" Deep Pantry Doors to be Designed and Installed Here. Goal: organized dry & non-refrigerated foods, appliances & whatev
100 gallon watertank
Base Structure
Support Slats
Water heater(left) & Chair Backs
Water heater on Plumbing Side
Seats Angled to Comfort
Now to commit and attach
Coin Pattern Rubber Matting Under the Water Tank
80/20 Staged to Asesmble
Final Look with Upholestery from A Foam & Fabric Place on 4th Ave
Pre-Sink Installation
Power Play: Battery Install and Programming. No power struggle here.
Two Epoch Pro 460 amp hour 12v batteries wired in series for a 24v effect managed by Victron System. Thanks to Explorists Life for schematics wiring diagrams, installation plan, recommendations for the whole system from components to tools, cables and lugs.
Hefty Epoch Pro 460Ah Battery, 12v
Assembling systems on a board in the shop
Multiplus to Inverter 24v 5000amps
OrionXS 1400 smartchargers for alternator charging
Lynx Distributors (top)
24v to 12v converter (left bottom)
Solar Chargers (bottom): Large Array (middle), Small Array (right)
Multiplus II Inverter 24v 5000amps
OrionXS 1400 DC to DC smartchargers for alternator charging
Top wires connect to Solar Panels
Epoch Pros in Series
Whole System Under Dining Room Seats
Butcher Block Counter above and draws to be installed in front of the Inverter
Goal: Road & Mountain Bikes, tables,... eventually, tool pegboards. Originally we would also house our kayaks here, but we opted for a new additional box on the back.
This arrangement is part of the prototype process figuring the angles and pieces needed for the fork mounts.
Blank Slate, Lines are the Hydronic Heating
Lonseal Man Sized & Glued
Slideout Full Length Shelf
First Setup: Road Bikes & Kayaks
Developing the Diner Table Talk & Counters
Excited to create a living space, we commissioned a local woodworker Alex Bristol at Spirit Woodworking to make us a beautiful mesquite table, with an extention, to make our dining room with plenty of room for board games. Our trip to Flagstaff for Art in the Park in July 2025 made a table an immediate need, even if there is nothing else in the box. Unfortunately the table mount from does not work with something so solid, even with a plate of steel mounted inside the garage on the back wall. Wobbly, moving back and forth, etc. the intention that we would be able to push the table out of the way or slide it along to wall like the mount claims, fell short and John had to do significant modifications and add a leg. Luckily Catalina the dog still fits easily underneath.
Table by Summit Shelves & Spirit Woodworking with Extension
The Mount claims to be able to easily move side to side. But that mobility makes for a shaky table that rubs and bangs on the wall.
Lagun Table Mount. Not usable for any but the lightest table. Fail.
Backend Shift and embracing Rivet Nuts
Needing more space for the Uru Oragami kayaks, fishing poles, and whatever else is better not kept in the Garage Cave.
RC Industries created and powdercoated this box to John's tight-tolerance specifications to just fit the kayak bags. To get it on there and allow for future adjustments or additions, John used the existing RivNut from the tire carrier, and then added a bunch more. The rivnuts
RC Industries Box Example
Original Look Sans Tire
Blank Slate for drilling ~24 holes
Aluminum Rectangular Tubing
Inserting rivnuts to hold boxes
~4 Rivnuts per slat to attach
Powdercoated
Plate tapped to anticipate for any ot
RC Industries Box (left) ready to mount using a mobile welding table and pulley system
Ta-dah! Ready for the Uru Kayaks
Clean slick look, now to get the tire up there...
GlueLam beams in the ramada levraged completely to do the job.
Tire Rotation Time. Formidable challenge for the one wolf wolf pack. Using every tool in the arsenal, including winches and the patience to remove 16 lugnuts per tire on the Hutchinson Rims for the X Force ZH Tires. Time determines the rotation, not miles on the road. ~ March 2025
Driving back from Detroit and the days afterwards, we figured the placement of equipment, electronics, water heater, tank, batteries, etc., and compared the heights of surfaces with the cab-over camper we've loved so much and used so hard.
This "Contest" to show off overland vehicles and teach others about how to live in the back of beyond on the road, was populated by complete vehicles, mostly 4Runner or Landrover-types, that were well and currently used. With ours as an empty shell, we had to create the vision for the event visitors and voters. We filled the space with powerpoint slides explaining our intentions.
At the Overland Expo it is often recommended to build your interior plan life-sized so you can have a real vision and trying to function in that space. To do that, we bought large plastic screws that come in a STEM student building set, and created our counters, bench and sink spaces.
Problem Paint
Always under cover and only used once, the paint on the box has begun to peel. The warranty can't be covered in Arizona, so Mike from ADVMobil says he will pay the gas for us to drive up there and have it repainted, this time with a proper primer.