design and construction of an expedition camper - part 1

 

I decided to start a new series with a more appropriate title for the design and construction of my expedition camper, so here it begins. I am breaking from my normal photo-rich posts for this one post as I begun with a top down design by first enumerated a wish list of things I want in the camper.

The list is not compiled with wistful thinking alone but with iterations of brainstorming comprehending the many constraints. As such the items are realistic and realizable given my rough estimated budget of $100k for taking the rig to completion. I would be doing most of the work except the specialized fabrication work that I cannot do without the needed equipment and tools.

It is all too easy to create an unrealistic list. I try to be realistic giving the limited space of the habitat box, undercarriage space, and energy sources. For example, to think you can power an air conditioner off solar and batteries is a pipe dream. 

So here goes the requirement list:

• diesel hydronic heat augmented by engine coolant heat via heat exchanger
• hot water heated by the diesel hydronic heater via a calorifier
• minimum of 10 gallons of propane for cooking and on demand hot water heater
• a well equipped kitchen with more surface than that in Brunnhilde
• sensibly sized stainless steel kitchen sink with European faucet
• custom solid surface countertop with milled in drainboard
• two or three hobs cooker with oven - built in broiler desired
• extractor vent above the propane hobs
• no microwave oven
• storage with generous cookware and serving ware
• wine storage capacity of 2 cases
• Japanese compact on demand water boiler for kitchen sink and may be shower
• 22" deep kitchen counter top above cabinet with generous storage
• largest marine grade 12V compressor based refrigerator with separate freezer
• additional 12V compressor chest freezer
• 75 to 100 gallons of fresh water in heated space
• water filtration system with UV sanitation (wish list only)
• DC water pump for drawing from stream - wish list only
• 40 to 50 gallons of grey water storage may not be in heated space with remote control drain valve
• no black water tank
• cassette toilet or urine separating toilet (leaning towards the latter)
• full bed with firm mattress with Froli bed spring system as in Brunnhilde's upper berth
• tilted bed board for comfortable reading or computing
• maximum overhead storage cabinet
• maximum storage cabinets and drawers
• cabinetry to be built with plywood by me
• indirect LED lighting plus task lights
• toilet with sink and with hydronic radiator/towel warmer
• compact retractable laundry drying lines in toilet
• shower located at entry of the habitat box - preferable with Japanese on-demand hot water heater and European fixture, and teak floor grate
• mosquito screen at habitat entrance
• 120Vac 9000 BTU inverter mini split heat pump/air conditioner
• Korean mini clothes washer/dryer
• 800W minimum solar panels with lithium battery system
• power inversion system located in relatively good access for service and monitoring, but without overkilled design, complexity, or cost
• storage for a Honda 2200W generator and fuel
• foldable stairs for the habitat box entry with a slide out platform
• cab to habitat box crawl through passage
• raised bench seats with dinning table for 3 to 4 that can be converted into a twin bed
• LTE cellular booster
• Starlink mobile internet
• mobile audio sound system in habitat box
• security security cameras
• sentry lockbox
• storage box above the truck cab
• tow hitch receiver for up to 7,500 lb of towing capacity
• 3/4" ratchet torque wrench for spare wheel changing
• dual stage bottle jack
• spare wheel carrier with manual winch
• built in 12Vdc air compressor with tank
• storage capacity for the essential tools and self-recovery equipment
• storage for a small chain saw, hand saw, and axe
• storage for a small propane or a Snow Peak wood grill
• 270-degree awning
• double the diesel fuel tank capacity of existing 33 gallons
• citizen band radio
• overlander GPS navigation aid
• improved sound system in the rather spartan cab
• outside propane hookup for outdoor cooking and grilling
• the best utilization of the garage TBD as I want to leave it for flexible uses

As I compiled this list I had been doing research of what equipment and components can realistically procured here in USA. USA is a shitty country to get the good motorhome products. I want a design and finished project at the level of quality German or Japanese camper that costs in the range of a good car to up to 500 Euro.

With the long wishlist of items, I should list the basic vehicle spec sheet as well the reduced weight capacity due to the conversion from dually rear wheels to super singles.

Fuso Canter FG4X4 spec sheet

the baseline actual weights of the rig on the return journey with 3/4 tank of fuel is 4960lb front/ 4220lb rear