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Old 06-25-2015, 07:45 AM   #41
ddunaway
 
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Default Re: PAV Adventure 4x4 Build

Quote:
Originally Posted by LooseRocks View Post
Trailer hitch ski rack? Probably the same price as a ladder for your van. Boots will still have to go inside but it'll be better than climbing up the side of the van.

Something like this:
http://www.rackwarehouse.com/inno-in...snowboard.html
Skis get all corroded surprisingly quickly riding outside exposed to road grime and elements. Ideally they are sealed in something. I suppose a bag on a rack could work.
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Old 06-25-2015, 03:28 PM   #42
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Default Re: PAV Adventure 4x4 Build

Quote:
Originally Posted by ddunaway View Post
Skis get all corroded surprisingly quickly riding outside exposed to road grime and elements. Ideally they are sealed in something. I suppose a bag on a rack could work.
These thing are interesting. They show them strapped to the roof in the second link. Maybe strap them to a trailer hitch rack. Wood coffins are probably cheaper but you can used these for travel also (assuming you travel far afield to ski).

https://www.sportube.com/Ski-s/1814.htm
https://www.sportube.com/Roof-Rack-S.../rrstrpspk.htm
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Old 06-29-2015, 07:19 AM   #43
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Default Re: PAV Adventure 4x4 Build

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Originally Posted by LooseRocks View Post
Wow, never seen those before. Those could strap on the roof or go on back or even inside I suppose....wonder if they are water tight?
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Old 06-30-2015, 08:28 AM   #44
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Default Re: PAV Adventure 4x4 Build

Big progress last weekend. I basically finished most of the initial electrical and successfully testing it all including the MaxAirfan and the Espar D2!!! Still need to sort out the exhaust on the D2 but at least all the little wires, Dsubs, and fuel line shenanigans are done.

Current Electrical Setup
My electrical setup is pretty simple given that it is all DC. All wires feed under the driver's seat down by the drivers side B pillar. It is all reasonable tidy. The crux was finding some fuse bars to fit under the MB fuses and making a bracket, so it all fit nicely.

I just need to run the solar wires through the roof to be "solar ready".....next few days hopefully. Working toward the milestone of re-installing the headliner. Lighting is the other thing to figure out before headliner goes up.....
Attached Images
File Type: jpg Fuse Bars Under MB Fuses.JPG (93.1 KB, 932 views)
File Type: jpg Underseat wiring 1.JPG (130.5 KB, 952 views)
File Type: jpg underseat wiring 2.JPG (140.5 KB, 888 views)
File Type: jpg Wiring along roof.JPG (131.9 KB, 950 views)
Attached Files
File Type: pdf Electrical-Now.pdf (89.4 KB, 334 views)
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Last edited by ddunaway; 06-30-2015 at 07:28 PM.
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Old 06-30-2015, 08:40 AM   #45
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Default Re: PAV Adventure 4x4 Build

Future electrical plan
Here is what I plan in the near on the electrical. I will add 2 group 27 batteries under the chassis (in the new Hein tray). That will give about 285Ahr....should be plenty in super cold temps for up to a week. I'll also add a couple solar panels to run a refrigerator full time and keep the batteries topped off. In addition, there will be one more fuse box in the driver side mid ship, so I can easily add more stuff as plans evolve.

The idea of the switch is that I can isolate all the loads, connect to the MB battery, connect to the other 2 house batteries, or just have it all hooked together (which will probably be most of the time). For jumping I could just separate the MB house from the other 2 house batteries and connect 1 small positive jumper cable under the hood, since the starting and MB house are the same type of battery.

Please offer suggestions.

Outstanding questions..
- Missing a few fuses on the batteries?
- Add battery monitor?
- Should just ground my house batteries to chassis somewhere or run wires all the way to connect to the MB auxiliary battery as shown?
- Lighting - I plan to replace the factor headliner light bulbs with LEDs. Should that circuit be put on the house batteries or is current draw so low that it is unimportant? I ran my wires to those locations in case I decide to move the circuit to the house side. Ideally, one might have the switch take power from the house circuit on the always on switched mode, and then still have the switched lighting working when the doors open. I do wonder if I can make that happen by placing a connector that jumpers in the House power on one of those circuits between the 1st switched overhead light and the MB wiring ......worried that it might mess with the MB electrical magic if I get too cute here though.
Attached Files
File Type: pdf diagram-near-future-2.pdf (141.3 KB, 282 views)
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Last edited by ddunaway; 07-01-2015 at 06:14 AM.
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Old 08-03-2015, 05:12 AM   #46
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Default Re: PAV Adventure 4x4 Build

Final Espar Install Details

This little project touches a lot of aspects of the vehicle and really gives you a crash course in upfitting. The last 20% took a while to finish.....mostly due to where I wanted the exhaust and fear of melting the fuel line.

It's under the passenger seat....
Attached Images
File Type: jpg flat spot under pass seat.JPG (84.9 KB, 846 views)
File Type: jpg installed under seat seat.JPG (97.5 KB, 809 views)
File Type: jpg warm air out.JPG (127.4 KB, 811 views)
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Old 08-03-2015, 05:19 AM   #47
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Default Re: PAV Adventure 4x4 Build

Exhuast

I did not want the exhaust to come back in open doors or windows. When I initially decided to do the under passenger seat install, I did not realize that most people put the exhaust close to the slider door. I wanted to run the exhaust out near the drivers side rear wheel. To do this I transitioned to 30 mm tubing after the heater which is mounted close to the heater. SS Espar tubing is not cheap and lots more brackets.....
Attached Images
File Type: jpg Muffler and transition from 25 to 30 mm.JPG (112.2 KB, 832 views)
File Type: jpg Exhuast running down pass side.JPG (116.4 KB, 819 views)
File Type: jpg 30mm exhaust our driver side rear wheel area.JPG (126.3 KB, 827 views)
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Old 08-03-2015, 05:33 AM   #48
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Default Re: PAV Adventure 4x4 Build

Fuel pump, fuel line and heat shielding

The fuel pump is mounted near the gas tank by where the fill tube goes into the tank. The fuel line goes above the tank and generally takes advantage of some holes that go thru the frame in various places on the passenger side. I went a little crazy on heat shielding.....how much is enough really?.....better safe than sorry. Anywhere that there could be radiant heat from the vehicle exhaust or Espar exhaust close to heater I ran the tubing through aluminized heat shield tubes. Anywhere there was radiant heat from the vehicle exhaust I also made heat shields that covered the tubing that was already in aluminized heat shield. I know...over the top.
Attached Images
File Type: jpg pump just behind fuel fill.JPG (82.2 KB, 769 views)
File Type: jpg fuel pump near fill for tank.JPG (104.6 KB, 711 views)
File Type: jpg Heat shielding into heater.JPG (125.0 KB, 712 views)
File Type: jpg Heat shielding above exhuast.JPG (95.6 KB, 693 views)
File Type: jpg More heat shielding above exhuast.JPG (117.7 KB, 719 views)
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Old 08-03-2015, 05:38 AM   #49
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Default Re: PAV Adventure 4x4 Build

Controller and High Altitude Sensor

The controller is mounted above the map light/overhead console in the headliner. Wait to install the electrical connectors on the controller till it is mounted in the location of choice or you get to cut and re-spice the wires to mount it (like I did). High altitude sensor is right behind it in the headliner.
Attached Images
File Type: jpg EasyStart controller above map-console lights.JPG (151.3 KB, 803 views)
File Type: jpg HA senor inside headliner.JPG (168.7 KB, 775 views)
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Old 08-03-2015, 05:57 AM   #50
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Default Re: PAV Adventure 4x4 Build

Solar

I wanted to have enough solar....
  • to run a DC refrigerator full time
  • to give some power in the winter to allow me to stay longer in one place and run the heater
  • to keep the batteries fully charged w/o ever having to plug in

I also wanted to keep my options open for the roof. I may want to put my rocket box up there at some point. I went with (2) 100W Renology rigid panels. They are mounted with Hein's adapters, which are compatible with a Fiamma. With 2 panels, I figure I can take one panel off and mount the rocket box next to it if I feel so inclined.

To take wires through the roof, I used some electrical connectors recommended by Graphite Dave (aluminum 1/2" NPT 90 degree cord grips, McMaster-Carr # 8317k2). I ordered a variety of other fittings that I did not like much.
Attached Images
File Type: jpg Roof w solar.JPG (117.7 KB, 871 views)
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