their new camper

FOLD-OUT for the future

By Nick Underwood

It’s 2.30am, when all freshly-minted retirees should be deep in a wellearned slumber and I wake with a head full of actions required before departure three days hence.

It’s been a busy few months passing the Western 4W Driver baton and overseeing the construction of our home on wheels with a plan to be completed well before this point and shaken down prior to our Flinders Fossick. As it turns out, our new camper will be unfinished but usable and, as the rego suggests, snugza bug in a rug. Why the change in off road accommodation? For 12 years now our canopy with rooftop tent and rear kitchen has been the ideal camper. It’s seen seriously remote country and been our home amid some of the most pristine and stunning landscapes in Australia - places we could never have towed an off road camper. So point number one - we prefer four wheels, not six. Point number two - we’re not as agile as we once were so scaling ladders with full bladders on freezing desert nights needs to take a back seat to comfort levels more appropriate to our retiring lifestyle. The decision was made at Ningaloo Station when we borrowed our mate Plugga’s hard floor Cub camper for a week on the beach.

Entertaining at Koonalda at the new digs. We were sold on the space it provided - big floor area, queen size bed, big annex area, outside kitchen and heaps of storage space. The only thing we didn’t want was it hanging off our towbar, so why not build one to fit on the back of the 79? From that point, the concept bloomed. Our transport of delight would include an indoor dunny, shower attached, slide-out kitchen and more USB charging points than you can poke a cable at (because I’m such a tech-head). In the months that followed, design fever wrung the creative juice from me at all hours with much measuring, drawing and squeezing everything in to the centimetre. Finally we took our plans to Darcy out at Option Engineering in Northam and construction began. To keep the weight down, the structure of the camper would be alloy on a steel subframe fitted to the chassis mounts. The biggest challenge for Darcy was to figure out how to incorporate an effective strut system, given we wanted our slide-out kitchen at the rear where a strut would normally reside. With that problem solved, construction gathered pace. Weeks later the canopy was at the local cabinet maker for interior fit out in marine ply, then off for a lick of exterior paint to match the vehicle (without matching all the scratches). When

In fabrication mode - all alloy on a steel subframe. Wiring everywhere as the electrics take shape.

the big day came, the old canopy was lifted unceremoniously from the cruiser and the new one ceremoniously settled into place. I snuck back to Perth with the old camper perched precariously behind on the trailer, relegated to second fiddle to our new hard floor fold-out. Next step was Auto Spark Osborne Park, where Tim and his crew wrestled with our shopping list. All electrics in and on the canopy are separated from the rest of the vehicle, except of course power feed from alternator and solar. From a lithium iron battery (fitted elsewhere), wiring snakes out to a central fuse box, then on to lighting, power points, compressor, water pump, inverter and oven with a couple of spare leads for future add-ons. While we were at it the 79 got a headlight upgrade and a couple of bar lights for

I worked closely with the boys at Autospark Osborne Park.

Meticulous work by Autospark Osborne Park

Linda and Steve at Original Canvas pulled out all the creative stops to come up with a custom-built covering. maximum spread close to the vehicle. As with everyone involved with the build, Auto Spark went the extra mile with all wiring braided and sheathed to reduce its visual impact. Separate to this system, an electric winch which operates the hard floor foldout is connected to the vehicle battery and operated with the vehicle running to reduce battery drain. Merging with the electrical work (and under increasing pressure to meet our deadlines), the vehicle was shuttled out to Original Canvas in Wangara where Linda and Steve measured up and began the canvas work. While based on a hard floor fold-out design, dimensions in this application varied to suit the extra height off the ground and Velcro replaced permanent fixing points to allow the canvas to collapse correctly on fold-up.

Waiting for canvas.

After several visits and some trepidation over whether the thing would close up easily with so much canvas in the mix, I took the set up to its next appointment at RV Lithium Systems Australia (aka Install-agadget) in Kenwick. Gadget is probably a bit of an understatement for cutting-edge lithium iron battery technology built to suit a given space and linked to Redarc’s flagship management system. Confirming Phil Bianchi’s impression in a previous edition of this august magazine, Paul Kearns is a guru and perfectionist when it comes to powering up caravans and campers and in a few days a 200 amp/hour battery was constructed and squeezed in with 3mm to spare and hooked up to the management system. With power to all points in the canopy, the final stop was at Off Road Equipment where an Easy Slide drop down fridge slide and ARB compressor were installed. With less than a week to go to departure, we threw ourselves into a flurry of furnishing

Inside it’s all luxury with queen bed for my queen and lighting and storage galore. Note the Porta loo for no more boots on, naked midnight dunny runs.

Canvas is a tidy fit that will tighten up more over time.

and fitting and finally, with no hope of a shakedown, took off for a couple of weeks in the Flinders. So what exactly have we ended up with? Starting at the top with the unit folded out we have a queen size bed under Australian canvas with power points either side. At the end of the bed, a standing space gives access to toilet (which can be moved to suit) and storage lockers. Sliding out from under the bed, two large drawers for clothes include a collapsible box-shaped laundry bag which increases in size in the drawer as clean clothes are used up. When full, the bag can be lifted out and off to the laundromat. Lighting inside includes a dimmable main light, a touch light in the standing space and overhead lighting at the end of the hard floor. A short, wide, three step ladder leads up to the bed and doubles as a step ladder outside to help with closing up. Hard floor area is a massive 2400 x 1800mm - enough to set up table and chairs with room to spare in inclement weather. Three windows in the bed area and one at the end of the hard floor let in ample light and breeze, while barring the wildlife with midgieproof mesh. There’s a canvas door either side with the right hand door leading directly out to a shower with its own base fitted to the hard floor, fully enclosed and well off the ground. No more struggling to get clean feet from shower to boots for these little ducks. To close the whole set up a strap runs from the rear of the hard floor, over the tent to a small 2000lb Warn winch fitted on the roof rack which draws the floor up and over into the closed position some 300 mm lower than our previous rooftop set up (our carport breathed a sigh of relief). Moving outside to the canopy access, gull wing doors lift to reveal a range of compartments sized to suit specific items - all easily accessible. Starting at the front on the right hand side, a 53 litre water tank with clear hose to show fill level sits below a tunnel space

Dirty clothes ready for washing. His ‘n’ her’s clothes drawers include collapsible vinyl laundry bag which expands as clean clothes are used up.

A Warn winch controls the ups and downs.

RHS is seriously compartmentalised.

which runs clear through to the left hand side. This will accommodate long items such as rods to assist with the transport of fish from ocean to plate (he says with eternal optimism), step ladder, axe, fuel cans and, dare I say it, generator for when the sun don’t shine and we want to stay longer. Next step back is the Engel 32 litre on a Piranha slide and sharing space with the canopy’s power base. Squeezed behind the fridge is the lithium iron battery, while above the fridge sits the Redarc manager complete with extractor fan to circulate good air in hot conditions. More on this system later. Moving rearward, dedicated spaces for chairs, table and other gear sit above an MSA slide-out (all the way) tool drawer complete with strip lighting plus an additional drawer for spares and other kit. Front locker below this side houses compressor and recovery gear while rear locker is for rubbish. The entire side is illuminated by LED strip lighting on the gull wing door. The left hand side of this set up is the living area, which comes with a full length awning, 2.5m wide with individual mesh walls which can be configured to act as a windbreak or fully enclose the space with its own entrance. Full skirts on the vehicle stop wind coming under and completely mozzie-proof the entire space. The kitchen area, as with the large interior, bed and toilet, continues to fulfil our wish list. At the front a 900mm insulated vegie and bottle storage drawer slides out under the tunnel. Next door our National Luna fridge now sits in a drop-down slide for much easier access and above this space an awning storage space also includes a 600W inverter. For our drop down slide we chose the Easy Slide from Clearview

Kitchen has much more surface space than our old set-up.

Susie loves her new kitchen. Note windshield for cooktop. Vegie drawer will be insulated to keep vegies (and liquids) cooler.

Stainless steel work top folds up to hold drawers in.

accessories. While it’s not a light piece of kit, it’s seriously robust with minimal side to side movement, smooth action and best of all Susie can poke around in it without the need to step up or employ block and tackle. Continuing to the right a stainless steel drop-down bench also serves to secure a set of the ubiquitous plastic drawers plus large built-in drawer with paper towel and oven above. To the side, plate, cup and glass storage sits next to a water hose connected to a 75 litre tank (both polyethylene tanks from Rota Moulding in Midvale) under the vehicle via pressure pump and filter. Lastly a stainless steel kitchen slides out 1300mm to reveal two utensil drawers, a slide-out washing bowl holder, three burner Thetford stove with moveable wind guard and fold out bench space extending the whole to 1800mm.

How we survived without a drop down fridge slide we'll never know.

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Slide-out kitchen has two utensil drawers and a slide-out washing bowl holder.

Lighting on this side is all LED with a strip facing out from the gull wing, two facing in (all dimmable) plus a strip inside the storage area to further illuminate the interior. USB and lighter power socket complement the inverter and lockers on this side are for gas bottles and additional pots and pans.

The shakedown

Fast forward to the first day of a two week tour and there’s no room for failure. Getting used to a new set up can be daunting, especially when it’s much more complicated than the previous. Starting with opening and closing the camper, my beloved was the winch controller while I hustled from side to side ensuring canvas was tucked in and everything was happening as it should. Stressful and frustrating till we got the hang of it when with a few alterations like shock cord to pull the canvas in as it closed, we felt a lot more confident.

AN ELECTRICAL LEAP OF FAITH

Ironically our extended stay up at Ningaloo last year also highlighted the limitations of our wet cell dual battery system. Extreme temperatures in high winds coupled with a few cloudy days left our solar panel literally ‘under the weather’ and our power supply heading south at an alarming rate. Truth be told we were probably asking too much of the system in the first place with two fridges on the go, but there you go - needs must. In our new system we knew we’d need more output and better charging options given we plan on propping longer and more often. We also knew weight would be a big consideration given we were carrying, not towing, our new home. Consequently it was a no-brainer to go down the Lithium Iron (LiFePO4) path. Lithium batteries are much lighter. For example a 100a/h Lithium weighs around 12kg compared to a 100a/h AGM at 32kg. In our case we get a whopping 200a/h battery weighing just 25kg when its equivalent in AGM would be closer to 100kg. Lithium batteries, as you are probably already aware, have a much longer life cycle, have far greater usable energy and recharge three times faster than lead acid. What you may not have known is that LiFePO4 batteries can be built to fit different spaces which to us in custom mode is an absolute boon. Initially we were looking at one battery split in two and with dimensions approximately 500w x 400h x 80d each until Paul at RV Lithium Systems found a better space for it and it became 450w x 400h x 180d. Our 200amp/hr LiFePO4 battery was built linking eight single cells together and featuring dual circuits so if the battery hits a low of 20% it will turn off all accessories and recharge.

The eight cell Lithium battery went in with 3mm to spare. Manager30 clings to the top while panel for the monitor includes a fan for high temps. Paul at RV Lithium Systems is a creative genius on battery system fit-outs.

Nearly all the improvements to our camping life as incorporated in this design worked a treat. Interior space, privacy, bed size, toilet and shower are excellent. Living area with drop-down fridge, vegie drawer and slideout kitchen are a vast improvement over our old set up, apart from what my beloved has named the “snapping cupboard of death”. The aforementioned plate, cup and glass storage area is a bit difficult to get at and the experience is further sullied by a roller door that snaps shut unannounced and much to her chagrin. As you can well imagine, this space is now my domain and will remain so until it’s fixed. Weight? Not yet measured, although I’m confident it will come in under our 3900kg GVM.

At 40% it will turn all accessories back on again. This Lithium iron battery will also charge in temperatures up to 65°. The benefit of this scenario for vans and motorhomes is obvious. Note: Lithium batteries (many from China) also come in standard sizes for direct battery replacement in areas other than under the bonnet (where the heat will kill them). What was crucial to the effectiveness of our battery system was an equally efficient management system and we went straight to Redarc for their Manager30. The Manager30 is right up there at the sharp edge of battery management with a charging profile specific to Lithium batteries as well as lead acid. Whether the input is from 240 volt, vehicle alternator or solar, the Manager30 automatically selects the most appropriate source and when possible, goes for solar. Now when we want to draw down fridges on house power prior to departure it’s just a matter of plugging into the Manager30 instead of changing power cords on fridges and all the rigmarole that goes with it. Apart from these great features, the Manager30 is also a dual battery isolator, load disconnect controller and a remote monitor. Paul out at RV Lithium Systems Australia likes the fact it draws all inputs through one unit and says the storage mode for lithium is exceptional. We like the remote display module that, at the press of a button, shows current levels, how long they’ll last and where charge is coming from at any given time plus a heap more specific detail. On our trip, overnight with fridges, lights and occasional music the battery never dropped below 88% (and if I’d backed off the freezer at night it would have looked even better.) Over 36 hours at rest with only a bit of solar input the battery slipped below 80%. So far we’re seriously impressed but the true test will be back up at Ningaloo at the end of August when we’ll be propped in one spot for ten days. We’ll run daily monitoring and report back in the next edition.

Cost? Well north of 50 grand, which sounds like an awful lot, but when we take into account it’s all custom-built, exactly what we want and comparable to many top end camper trailers without the associated towing issues, we’re more than happy with the result. Next stop, back up to Ningaloo where it all began and where our new wandering life begins. A big thanks to the following for their outstanding input to this project: Darcy at Option Engineering, Northam Leon of Avon carpentry Tim and Jamie at Autospark Osborne Park Linda and Steve at Original Canvas, Wangara Paul at RV Lithium Systems Australia

Among many features the Redarc Manager monitor displays current rate of charge and source of charge. You'll see more when we test the system out over 10 days up at Ningaloo.