Preparing your rig for the Big Lap
Date: 17.07.2012
How the Paveys modified their Track Trailer Topaz before their journey around Australia.
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Generators and awnings provide comfort on the road.
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Setting up a long term tourer is a complicated and ongoing
business. So to get ready for our year-long 'big lap' of Australia
we needed to modify our Track Trailer Topaz camper trailer - so
that it perfectly suited our travelling needs.
If you are not familiar with the Topaz, it is like a bigger Tvan.
It has a similar go-anywhere ethos, but is combined with caravan
comforts. While flexible bedding (king, queen, singles or a bunk
option), multi-positional table, inside or outside cooking, easy
deploy awning, 80L fridge/freezer and onboard hot water make it
easy to live with straight from the factory, we have made a number
of modifications that have really enhanced it as a long term
tourer.
ELECTRICALS
Determining our energy demand was a challenge - how many amps would
we burn each day? How would they be stored? And, most importantly,
how would we replenish them? We trawled through a number of
excellent resources including www.dynamicsolarsolutions.com.au,
www.campertrailers.org
and Collyn Rivers' The Camper Trailer Book. We listed our
electrical devices, estimated the current draw per item (amps),
estimated hours of use each day and summed the values to get the
total daily amps we required.
GETTING POWER
The real fun began when calculating how to replenish our energy using solar, for when we would not have access to mains power or the alternator. Estimating solar power generation is a tricky business. There are so many variables - panel size, type, efficiency, cloud cover, temperature and peak sun hours. To make things more complicated, the rating of panels is a little misleading. Panels are rated at peak power which is often generated at voltage that is not useable, such as a 120W panel which generates at 16.5V. When measured at 12V, the power is around 75-80% less. So multiplying panel sizes by 75% gives a more accurate idea of energy generation for 12V applications, in ideal conditions.
After messing around with spreadsheets and estimates for a few
weeks, we had a chat with Jamie Hazelden from Dynamic Solar
Solutions, who recommended the Redarc Battery Management System
(BMS), BMS1215. This system features a display showing inputs and
outputs in real time and battery reserves for each hour and day
over the last 30 days, which we used to audit the camper's
electrics. Switching on each item one at a time, and then together,
it quickly provided a more accurate indication of our electrical
demands. Similarly, with our solar panels or generator deployed, we
could see how many amps were being generated and how long it took
to fully charge the batteries.
Our most power hungry device is our 80L fridge/freezer, drawing 6Ah
when running. In the warmer regions the fridge can run almost
continuously, one of the problems with all compressor fridges.
During extended stays in one spot, we planned to replenish this
draw with solar panels, using the generator as a backup.
So we went back to Dynamic Solar Solutions to discuss solar panels.
Our preference was for permanently mounted hardware that wouldn't
affect the Topaz's centre of gravity. Jamie sourced a pair of
Unisolar PVL68 amorphous solar panels, super thin and weighing only
4kg each. They don't generate as many amps as a similar sized
multi-crystalline panel, but perform better in the tropical zone,
as increased temperatures don't affect the output. They were
permanently mounted to the roof of the Topaz which meant they could
charge the batteries back at camp while we were off exploring,
whilst still being secure. The only trick is keeping them clean, as
roof access is tricky when your camper sits on an offroad, high
clearance axle. Standing on the front storage box with a soft broom
dunked in a bucket of water does the trick.
The downside to this approach is that we must park the camper in
the sun to generate solar energy, making it hot and making the
fridge work harder. To help with this problem we got some CGear
awnings to keep the hot sun off the camper's body, while the
pop-top mesh enables airflow. Track Trailer added strips of
aluminium tracking to the camper to attach the awnings, pegged at
an angle.
For the colder months when peak sun hours are less, we had a chat
to Generator Place. They have a great website or you can freecall
to talk to a generator expert. With the Topaz sporting a 1200W
Truma air conditioner, they suggested we get the Honda EU20, rated
to 1600W (2000W max) if we wanted to run the cooler or heater at
remote locations. So far, the air conditioning has saved us in
stifling hot conditions at El Questro, Carawine Gorge and Middle
Lagoon near Cape Leveque.
STORING POWER
With the energy demand and replenishment side of things
adequately addressed, it was time to look at how to store this
energy. Twin Optima 76Ah yellow tops just managed to squeeze into
the battery trays and while their storage capacity is smaller than
some other deep cycle batteries, the Optima spiral bound coils
recharge quickly, are vibration resistant and withstand deep
discharges better than other types of battery, giving them a higher
useable capacity.
The Redarc BMS enables the camper's batteries to charge to 100%.
It's widely accepted that alternators generally charge a vehicle's
battery to around 70% and trailer batteries fare even worse,
topping out at around 65%. Considering most batteries can only be
discharged to 50% this leaves the battery with only 15% of usable
charge (65-50=15%) unless supplemented by additional charging
resources, particularly for longer stays.
In order to safely charge the batteries to 100% charge, the system
utilises a multi-stage charger to progressively top up the battery
reserves without generating excessive heat. It also controls all
incoming charging energy sources (240V, 12V and solar), keeping the
batteries primed at 100% charge. This facilitates improved
utilisation and prevents overcharging.
The BMS's final selling point was its ability to double the battery
recharging rate when used with our Honda EU20 generator, which
normally provides a recharging rate of 8Ah. With the BMS, the
output is more than doubled, rising to 15Ah. This reduces generator
running time, fuel costs and the associated noise. All in all, the
Redarc BMS is a very impressive bit of kit.
While in Adelaide, we stopped in at the Redarc manufacturing
facility to see how our units were produced. Redarc is an
Australian success story, locally manufacturing quality electrical
components and boasting a two year no fuss warranty. I can verify
as to the class leading manufacture and quality assurance in the
build, as we viewed components tested at varying stages of the
manufacturing process.
After the tour, we picked up a pure sine wave 1000W inverter
(SK1000) to power our 240V electrical devices when away from mains
power. These include our laptops, cameras, phones and batteries.
While we have used modified sine wave inverters in the past, we
have had issues with laptop hard drive failures, so these days
prefer the pure sine wave. While they cost a few hundred dollars
more, the cost savings are more than recovered simply due to the
reduced chance of fatal failures. The boys at Elizabeth Auto
Electrics took care of the fitting side of things, mounting the
inverter at the bottom of the wardrobe.
INTERIOR
Very little needed to be done to the interior of the Topaz, such is
its high level of comfort from the factory. But to make it more
cosy, particularly during the colder months, we laid carpet on the
floor. To cool it without resorting to generator power, we
installed twin Sirocco Caframo 12V fans. These help to circulate
the air and a timer system allows them to run overnight. They are
an excellent unit and consume very little power (0.21 - 0.34Ah
each).
We ran high output LED strip lighting along the ceiling, lighting
up the interior like a Christmas tree. The output is probably
higher than it needs to be, but suits our mobile office needs. It's
rumoured that something similar may soon appear on the Topaz
production line.
To assist with carrying a years worth of clothes and other kit,
additional storage pockets were attached to the walls using suction
hooks. The pockets have fared well, although they're not rated for
heavy items during bumpy offroad travel. Everything has its
limits!
EXTERIOR
Up front, we prefer the Hitchmaster DO35 drop on coupling, a
wide self-centering coupling that guides the locating pin home with
ease, making hitching up simple. We just have to remember to keep
the pin well lubed to assist in removal, particularly in dusty or
sandy conditions. A Vehicle Components hitch lock slides through
the coupling, securing the trailer, and a neoprene shin protector
minimises swearing on accidental impact.
To reduce marital confrontations the VMS Navigation System in the
Patrol is supplemented with a dual reversing camera kit and switch
box, with cameras fitted to both the Topaz and the Patrol. They are
a great addition, providing both day and night vision, and greatly
reducing stress. Money well spent!
We are running 17x8in Patrol alloy wheels on the Topaz, matched to
rugged Cooper STT tyres. Combined with the dual spares carried on
the Kaymar rear bar, we are carrying nine matched wheels; ensuring
three spares are available at any one time. The STTs have performed
above expectation to date, clocking up over 20,000km. Along the
Gibb River Road the tyres performed superbly, cutting through the
loose surface gravel to the sharp embedded gibbers to provide
excellent traction.
Sitting on the front storage box, a Thule dual bike rack looks
after a pair of Malvern Star XCS mountain bikes. Kudos to Thule for
building such a well-engineered rack, because despite enduring some
of the roughest roads in Australia, the bikes haven't even looked
like they are in danger. Arguably some of the credit should be
shared by Track Trailer for the way the MC2 suspension massages the
corrugations.
Taking care of stone protection duties, a Stone Stomper shields the
rear windows and the Topaz's paintwork. The Stone Stomper utilises
a horizontal truck mesh between the vehicle and camper to deflect
any flying debris. While we have used a custom made, extended rear
wheel flap unit for a number of years, the Stone Stomper is a much
better solution, providing improved protection and better
appearance, without limiting airflow around the rear diff. In
motion, the Stone Stomper also pads down dust, keeping our mountain
bikes and the front of the camper relatively clean.
When it comes to sharing a barbecue with fellow travellers, our
Cross Country 4x4 Stadium Light pumps out 1600 lumens of light
whilst drawing a mere 1.5Ah. The high output LEDs are mounted on a
3.25m bi-fold light pole, lighting a broad area and keeping the
bugs up high instead of around us.
Taking care of catering duties, a Sovereign stainless steel hooded
barbecue lives in a dedicated locker on the near side of the
camper, sliding out for use. While the campfire is the entertaining
centrepiece, the barbecue enables fuss-free outdoor cooking.
Well folks, that's an insight into how we've setup the Topaz to be
our home away from home for the next twelve months or more. To
date, all our additions have added value, making an exceptional
offroad camper an even better long term touring proposition. It
will be interesting to compare notes at the end of the trip, to see
what survives the brutal punishment that is offroad travel.
Source: Camper Trailer Australia #43
