2007 23C Rebuild

[Red Green]

I then moved onto the solar system. First were the solar panels.
I didn't want to poke any holes into the roof to fasten down the panels so this is how I accomplished the task.
I used 1/4" plastic corrugated sheets, cut to the size of my solar panels. (This will allow air movement under the panels to hopefully keep them cooler.) My flexible solar panels have 6 grommet holes for securing the panels. I poked the corresponding holes in the corrugated plastic sheets and used 6 round headed, square shoulder bolts. After I inserted the bolts into the plastic sheet, I cut a 2" wide piece of Eternabond tape 3" long. I cut a slot in the tape to slide it down over the threaded part of the bolt and then wrapped the other half of the tape down around the edge of the plastic sheet and then over the bolt head. I did all six bolts this way per sheet. Once completed, with the six bolts pointing skyward, I cut 4 more strips of EternaBond tape, 3" wide and 7" long. I cut a slot in the middle of the piece of tape and placed a piece of tape at each corner at a 45 degree angle over the plastic sheet and onto the roof. That leaves the cells in the plastic sheet open and allows it to 'breathe'. The sheet is now securely attached to the roof and no holes.

I placed one strip of 1" VHB double sided tape down the middle of each solar panel so that it wouldn't be apt to flutter in the center in high winds (like going down the road.)

We placed the solar panels on the plastic sheets, placed a washer on the bolt and then the nut. Smeared the bolt with liberal amounts of anti-seize, as well as applying it to my hands, my shirt, and my pants!
I repeated all of this for each panel.

I ordered some aluminum 1/4" transition strips from Home Depot. They are 4' long and worked great to place along the leading edge of each solar panel to direct the wind up and over the panel. A 2" strip of EternaBond tape runs full length of the transition strip. The finished project has no tape on the panels, (for easier removal if needed), and the wind can not get under them. (Unless of course there was tornado or hurricane coming in from behind the camped, I guess the then it might get under them, but in that scenario, I think I might have bigger problems than a missing panel!)

 

[Red Green]

I then moved into the the interior of the camper and went to work on the power supply system I had 4 LiPO4 batteries to install.
The original couch was removed before I bought the camper, and a previous owner had built a bed frame for a full size mattress. That gave me room to keep everything close but yet workable.
At first I was going to put everything in the water heater area, but decided to work it all into the wiring fuse/breaker panel area.

Where the power comes in from the 30amp shore power cord, it into a 30 fuse box. Coming out of the box, I placed a 120v outlet and also ran a wire over to the 30amp Transfer Switch.

The reason for the outlet is to plug in a LiPO4 battery charger that will only operate when plugged into shore power and will not operate while using the inverter.
The Transfer Switch is wired so that it can run either 120v current off the inverter and or the shore power, and the current will stay separated.

I was able to use the same length of cable to connect all four batteries to keep them balanced. (Same impedance across the batteries. (I think I said that right.)) Anyway, the batteries supply the camper with 12v current and 120v through the 3000 watt inverter.

I am currently running 400 AmpHours of battery and 3 - 200 watt solar panels, connected with a Victron 100/50 MPPT Solar Charge Controller. We will see how that works.

The controller is mounted in the overhead cabinet below where the wires enter from the roof in the left front of the camp over the bed. From the controller the wire drops straight down to the water heater compartment and over to the batteries.

I am thinking this winter, I may take the time to make the wiring look a little prettier.

 

[sam-HILO]

N ice work!! When is the maiden campout?

 

[Red Green]

N ice work!! When is the maiden campout?

Very soon!!

 

[Red Green]

Since I had most everything completed that I wanted to do. It was time to appease the DW. So, I replaced the flooring with vinyl adhesive planks. Since I removed the toilet to put the flooring under it, I also changed both toilet seals.

Once the floor was done, I hung the curtains that the DW made.

 

[Red Green]

It was finally time to pull it out of the shop! The last big thing to do was to install the awning back onto it. That went smoother than anticipated, and we were ready for our maiden voyage!

Last week the temps in Northern Wisconsin were in the upper 70's - lower 80's, and the fall colors are near or at their peak, so we headed to a National Park for a few days.
Our of the 47 campsites, only 3 other campers were there, it was so quiet and peaceful!
Everything worked as expected, (or better than expected!) The solar panels didn't top the batteries off, (we were parked in the shade under a lot of trees), but the panels did keep the batteries in the 70 -85% range.

 

[Red Green]

The trip was a huge success! We are pleased with the results.
The only thing at the moment that I can think of that I would differently, would be the 4x4 beams that I cut for the lower frame on the upper half.

What I did worked well, but the longer 4x4 has a slight bow to it, and the one by the door has a twist. I think in retrospect that maybe a cedar 4x4 maybe would have stayed straighter, or maybe a laminated 4x4 like 2 - 2x4's or something like that. But, as we would say when something didn't turn out perfect, "Well, it is just a camper!"

But, we love our HiLo, and can't wait to go camping again!!

Thanks to everyone that followed this long drawn out process, and for all the encouragement! It has been quite a trip!

And yes, after I took the last picture, I lowered the hitch one notch to level the HiLo.

 

[r67northern]

Fantastic work. Very nice.

 

[sam-HILO]

I love a happy ending to a long story. I wanted to go camping in these bonus warm days. Too many chores to do at home. I have made some reservations for next year. Hindsight is a great thing!! Someone will benefit from your wisdom. Going to rain and be in the 50* this week. Then a few days in the 60*. Time to put the lawn equipment away for the season. It takes two days to change oil,sharpen blades.new filters and possibly paint the riding mower deck.