I appreciate your patience as I continue to try to catch up with posting updates here on my progress with the transformation of Lance from his start as a 2016 Kenworth T270 Medium Duty ambulance from a fire department in Wisconsin to an eXtreme RV or XRV for us to continue our explorations via our Land Yacht. I’ve got a few more updates to do but I just about have you up to date on all the various projects within Lance and this one will take you through the completion of the Head & Shower area inside Lance’s Hab/Habitat/Happytat ambo box.
Last month, May 2026, while I was still at our place down in the very southern tip of Nevada which we call “Road Runner Ranch”, I was able to finish building out the Head and Shower area in Lance.
* FYI, Christine and I are still sailors at heart so the Bathroom will always be the Head and the Kitchen will always be the Galley for us.
I drove Lance up to our place on Saturna Island mid May and am now working up here at finishing off the interior while we are up here through end of August.
Here is what I was able to get done before that drive;
To help with your orientation, this screen shot from my Fusion 360 3D model shows where the Head & Shower are located in the front DS Driver Side of Lance’s Hab/Habitat/Box which is on the far Right of this view. The Settee & table are at the opposite back end on the far Left with the Galley counters spanning both sides in the middle.
Note: You can click on any photo to enlarge it.
Here is what it looked like IRL (In Real Life) from the inside when I got started. That’s the SS Fridge/Freezer on the far Right, Blue DS Galley countertop peeking through on the Left and that’s the DS Front corner of the Hab in the far middle of this photo. The toilet will sit on top of the raised floor section and I’m getting ready to put in the the shower pan on the lower section of the floor that the blue cargo spreaders are resting on.
The framed in area above the Head will be a storage cupboard on the larger Right side portion and then the smaller space created on the Left will be a service area for plumbing and electrical which I’ll cover later on in this post. I started prepping the interior by gluing 1/2” Baltic Birch plywood on the XAL eXtruded Aluminium framing of the two walls you see here on the Left and Rear. I use these adjustable Blue Cargo Spreaders (from Harbor Freight) all the time and here they are helping apply pressure to the freshly glued in BB plywood panels to keep them flat and straight.
The small box protruding into the Head area on the bottom Left is the front end of the large middle exterior compartment you saw me filling up with all the plumbing and heating systems in the previous post. For maximum adhesion of the rigid foam Shower Pan I removed all the LVT vinyl floor planking that covers all the floor area inside Lance’s Happytat. To help with tiling the shower pan and getting the slope to the center shower drain just right, I bought a Vevor shower pan kit that is specifically made for this purpose and adds even more insulation to the shower floor. It is covered with a thin gray felt that grabs the thinsulate/mortar bedding compound I’ll be using to bed in the electric grid for the heated floor and the ceramic tiles. Very nicely designed bit of kit and the floor foam is cut in half with the felt glued on top to act like a hinge and made it much easier to press fit the floor into place after cutting it to size. You can see here how the area for the flange of the PVC drain is already pre-cast into the foam and you’ll also note the large circular recess surrounding it for bedding the drain flange into the floor. After checking that it all fit just right, I removed the foam pan, applied a silicone based adhesive with my cordless caulking gun (that I’m enjoying more ever time I use!), spread it out evenly with a notched trowel and pressed the floor pan back into place using my trusty cargo spreaders and some aluminium and plywood cauls to press it even and flat. It was difficult to see in the photos above but I also used 1/2” BB plywood to cover the wall between the Shower and the Fridge/Freezer compartment. I caulked all seams and corners with construction adhesive for additional sealing of those.
Next I put in this small bit of XAL framing to extend that exterior cabinet “bump” all the way to the inner edge of the Head raised floor. This will also create a handy storage area.
The black lines you see on the White ACM Aluminium Composite Material of the Head Floor is from me laying out the spacing for the heated floor electric grid you’ll see a bit later below. Now it was time to completely waterproof every surface inside the Head & Shower to ensure that there are no leaks in the future. I used the ever popular RedGuard and brushed it on all the surfaces.
After the first thin coat of RedGuard was on I went around and used more RedGuard to bed in some reinforcing felt that I cut into strips and pressed into all the corners and seams with more RedGuard. The drain area received several more coats of RedGuard as this will get the most traffic and potential for seepage. The pink colour is from the still wet RedGuard which quickly changes to Red as it dries fully. Et Voila!!
A very Red and very waterproof Head & Shower area. A bit messy but my 11cm/ 4 1/4” hole saw did a nice job of cutting this hole through all the layers of insulation and aluminium in the floor for the PVC drain to set into and exit out the bottom where it will connect to PVC pipe and on to the Gray Water tank. You can also see the 2 inches of insulation that are below the shower floor. I had some of this Blue Solid Surface acrylic material left over from doing the Galley countertops so I used this to create a nicely contrasting and durable shelf top on that bump out in the Head. This solid acrylic material is heavy but is very nice to work with; cuts easily and cleanly with regular carbide saw blades and router bits and then sands/files nicely to create a polished surface. I wanted to get this shelf installed before I started putting in the PVC planking that I’m going to use to cover the walls.
TOASTIE TOOTSIES!
As I mentioned in the previous post about our diesel powered Oasis Zephyr boiler, the rest of the floors inside of Lance are heated via the hot glycol (anti-freeze) pumped out of that boiler and flowing through the loops of 1/2” PEX-A tubing embedded into the insulated foam below the LVT vinyl plank flooring. But I wanted to be able to control the heated floors in the Shower & Head separately as it is always nice to have warm shower floors even in warm weather.
So I opted for another Vevor product, this heated mesh flooring kit that runs on 220VAC and has its own thermostat. The kit comes with this Orange plastic mesh which the Black heating cable gets attached to.
Also came with this every nice digital thermostat for controlling and reporting on the heated floors. This is the transition piece where the cable changes from the 220VAC power cable to the heated wire. As it is a larger diameter I routed a groove into the ACM flooring so this thicker diameter would sit flush with the floor surface and be better protected. The heated cable is one continuous length and you can not cut this so it took me a bit of planning to get the spacing right but all fit in very nicely and will keep our tootsies warm both when showering and sitting on the Throne!
There is also a temperature sensor that gets embedded in the floor and provides this data to the thermostat so it can maintain whatever floor temp you set. I put this inside a length of protective tubing and that’s the L shaped length you see here which then exits out the side wall and goes up to the thermostat. I put this sensor in this larger diameter tubing so I could remove and replace the temp sensor if it should ever fail. With all the heated cable and mesh in place I mixed up the epoxy thinsulate/mortar and spread out about a 13mm / 1/2” thick layer with a steel trowel and smoothed it all out. Didn’t get a photo when it was done so this is part way through the process. Finally ready to start tiling!
TILE TIME:
We found this Blue & White Spiral pattern ceramic tile online and both really liked it so that’s what is going on the floors. Comes in these larger approximately one square foot sheets with individual tiles glued to a mesh on the back which makes handling and setting them much easier. Laying out this type of spiral pattern is a bit tricky and takes some planning to make sure all the corners and joints line up and maintain the pattern. If you look closely you’ll see that you can only get a straight line for butting up against corners or lining up sheets in one place along the larger square formed by each spiral.
I created a quick 3D model (of course!!) to help plan the layout to get all the corners and seams to match up. Where I needed to cut some of the tiles such as around the drain, my trusty Dremel tool with a diamond cutting wheel worked like a charm to get nice straight cuts and smooth edges and you can maybe see along the bottom edge for this sheet I’m trimming square here. It had been a Looooooooong time, think decades, since I last did any tiling so I started with the floor in the Head as it will largely be covered by our Joolca “Gotta Go” separating toilet to cover any learning errors, but it all turned out quite well I thought. Then I moved onto the Shower floor and started the dry layup there. You can see how I needed to trim the tiles a bit along the edges of the square SS drain which I did so that the outer edges of the regular square spiral patterns would match up with the outer edges. And it all slopes down from the edges to the drain. I thought it would look better to create a single upper edge surrounding the whole space so I put in some aluminium edging and tiled up to that along all the sides of the Shower and the Head floors and set them in place.
WALLS:
For the walls I wanted to find the best combination of waterproof, easy to clean and good looking so I ended up going with these White tongue and groove PVC planks that are about 18cm / 7” wide with grooves molded in to look like narrower planks, and started cutting them to size.
But I thought that all White walls and ceiling would be too bland so I decided to create a horizontal band to break up the walls that would wrap all the way round and fill this with some of the Blue & White spiral tiles I had left over from doing the floor. I picked up some aluminium edging meant to be used under tiles which you see propped up in the corner on the Right here and used that to make the transitions from tile to PVC planking. I taped off the top and bottom edges of the area for this band………….. ………. and installed the AL transitions edging all round. I had enough left over tile to cut these bands off the sheets and used that size to determine the width of the band. Worked out quite well and now time to put up all the PVC wall planks.
It was quite quick and easy to cut the 8ft long PVC planks to a nice fit between the top and bottom edges of the aluminium edging there the tiles start and stop. And now time to use my trusty Milwaukee cordless caulking gun you see on the Left of the floor to put a nice thin line of White silicone adhesive/sealant along each tongue and groove and back of each plank. The cargo spreaders and some square aluminium tube cauls helped to hold the PVC planks flat while the silicone adhesive cured overnight.
With the wall planks all done I could now grout all the tiles in this band and on the floors to finish the tiling. I did the ceiling with the same vinyl planking with a different pattern on it that I used for the ceilings in the rest of Lance. As with those other ceilings, I put in a strip of dimmable LED’s between each plank but more on that a bit later.
Et Voila! Lance finally has a not too bad looking Head and Shower.
LET THERE be LIGHT AND AIR!
We always like to have individual items do more than one thing and so we decided to install this 12V vent fan in the ceiling above the shower to provide both daylight and fresh air venting into the Shower & Head space. I’m not a big fan of the popular variations of the MaxFans that much of the RV and Van world seem to use and wanted to keep our overall vehicle height to a minimum and we’re at 2.9m / 9’ 5” right now with the solar panels and roof vent. So this Kohree vent unit seemed to check all our boxes.
This model also had a nice combination of both a manual override for raising and lowering the vent cover and a set of electric controls on the other corner of the fan as well as a hand held wireless remote.
It also has a temperature sensor to turn the fan on/off and a very quiet fan with 10 different speeds.
Other nice features are a built in rain sensor that automatically closes the vent though not much of a need when this is all inside that nice waterproof Shower. I had purposely left this space up on the roof in front of the four 450Watt solar panels and their Super Strut rails so now time to cut the only hole in our otherwise seamless one piece roof.
Yikes!!!! There are three thick aluminium plates in the roof of Lance, one for the top skin, the layer you can see here that forms the internal ceiling of the ambo box and then …… ……… the final layer of 5mm thick ACM that I installed for the ceiling surface below the additional layer of 20mm IPS foam insulation. The vent dropped in just right. I used this 2×2” square AL ceiling beam for a conduit for the wires to power and control the fan. I’m a BIG fan of these WAGO wire connectors and have used them throughout the build. They worked well to connect these 12VDC power wires to the fan and then tuck nicely into that square AL tube.
Checked everything for a good fit including this trim frame and then …. ………. bedded the vent into the roof with 3M 5200 sealant and some makeshift weights to let it cure overnight.
and MORE LIGHT!
As I mentioned earlier, I matched the ceiling in the Head & Shower to what I installed in the rest of Lance which are these planks of White solid vinyl with a nice grained texture and then put in strips of Black aluminium LED channel. I will then adhere dimmable COB LED strips inside these AL channels and snap on the diffuser cover.
All fully water immersion IP68 rated so no problems in this wet area. Worked out well to provide Goldilocks just right lighting both night and day. One last detail for those few times (so far) either of us needs to get up and use the Head in the middle of the night, I wanted also have some indirect low level lighting inside the Head & Shower area. So I installed some of these 45 degree angled aluminium extrusions in hidden areas such as under the door sill into the Shower you can make out below my hand and another under that little Blue shelf in the Head. To help keep our night vision and add a bit of “ambiance” I used these Blue LED strips which are also dimmable to whatever level of Blue light you’d like.
Testing out the LED strip tucked in below the door sill into the Shower.
DOORS!!!
After using Lance for over a year now with NO doors on the inside one member of the crew is eXtremely eXcited about having a DOOR on the Head!!! After some debate and research we decided to go with this retractable shower door that rolls up when OPEN like this ….. and then rolls out to seal and CLOSE like this. The flexible material rolls up on a spring loaded shaft hidden neatly inside this cassette that mounts to the left side of the door. The “door” slides on tracks concealed inside the AL extrusions top and bottom and I left a small gap at the top to help with air circulation.
FINISHING TOUCHES:
To keep things dry inside this storage cupboard above the head, I glued in some sliding door AL tracks and cut some clear 6mm / 1/4” acrylic for the sliding doors. And then mounted this mirrored Medicine Cabinet on the rear wall to finish things off.
SHOWER FAUCET:
You can’t have much of a shower with no water so along the way I installed this very nice adjustable hand held shower head that has a full shut off valve on the handle and …. …… connected it to a thermostatic controlled mixing valve faucet. These are great for maintaining a whatever water temperature you set it to coming out of the shower head. The button allows you to turn the water on and off as you wish to conserve water and have it off when you want to wash your hair, shave, etc. The SS cylindrical knob on the top end rotates to set the temperature and the one on the bottom controls the water flow volume.
To mount this I cut a sheet of 6mm / 1/4” thick aluminium diamond plate which fits just right into the slots of the 1” 1010 Series XAL framing. I drilled and threaded this plate to mount these two brass fittings for the thermostatic valve to attach to on the outside and push-connect fittings on the other side ………… …… for the Hot & Cold water 1/2” PEX-A lines to attach to. The Yellow handles are shut off ball valves on each PEX water line for servicing or winterizing.
The whole assembly then fits securely into the slots in the XAL framing.
CONTROL PANEL:
Finally, to enclose this service bay area I built this temporary panel and with many of our controls for the systems in Lance mounted on it. This is just a prototype I am trying out made out of scrap plywood with some of the switches, controllers and thermostats mounted in it. I cut this rabbet or tongue on the bottom edge that is a snug fit into the groove on the bottom length of XAL framing. The way it works is that you first put the bottom tongue into the groove and then …….. …………… tip the panel up into place. To hold this and likely all the panels in Lance securely in place, I’m trying out using these very strong round “donut” Neodymium magnets. This one is a 40 pounder, meaning it takes about 40 pounds of pull to remove. These magnets are available from less than one pound up to over one hundred. All the metal in Lance is aluminium which of course isn’t magnetic so cut a short 5cm/2” length of steel flat bar and drilled a 6mm hole in one end so I can bolt it to a T nut captured in the XAL slot on the back here. Worked out even better than I hoped and the panel snaps into place with a good “thud” and locks the whole panel tightly in place. But I only need to reach behind it and push hard with my fingers to pop the panel forward and out. Here is what the panel looks like so far. White thermostat for the heated floors in the Head & Shower in the bottom right (currently turned off) and the Victron Cerbo GX touch display above it and switches for things like water pump, Starlink power and the thermostatic controllers for the heated main cabin floors over to the Left.
I will likely change the layout a bit and add a few more switches and meters, but it all works for now and we’ll try it out on our travels in the next month and see what other changes we might want to make.
And th th th thaaaaats all for this update folks.
Hope it was entertaining and of interest to you and that you’ll be back for the next update in a few weeks.
We are going to be out in Lance eXploring more of Beautiful BC for the next few months till we head off to Europe at the end of August so I’ll do my best to get the last few updates posted for you. Next big project that I’m not starting on is to build all the Cherry veneered drawer fronts, doors and interior panels that will should pretty much finish Lance’s build.
Don’t forget to add your comments and questions in the “Join the discussion” box below and enjoy your summer wherever you are.
As we all head to the exit of 2025 I will continue to summarize the progress in various key systems and areas on Lance over the past few months.
This week I’ll bring you up to date on where the Galley is at so far.
Easily one of the most used and most important areas for our day to day live in Lance and our 10,000 + mile “maiden voyage” this past summer proved that our design worked well as we used it during that two month test drive. We prioritized large areas of open countertop, dual deep sink, induction cooktop and large fridge and freezer and you can see the basic layout from the 3D model screengrab here.
GALLEY COUNTERTOPS:
Here is what it looked like as of the beginning of June, just before we hit the road to the East Coast of the US. This is looking forward so Drivers Side DS on the Left and Passenger Side PS on the Right. Entry door into the Hab (Habitat/box) is on the upper Right with the large vertical door 10 cubic foot Fridge/Freezer on your Right as you enter.
Deep double sink being undermounted to the 25mm/1” solid surface acrylic countertop.
Lots of options for water at the sink; hot/cold adjustment at the base of the faucet with both a large flexible rinsing hose with its own nozzle & lever and then an independently controlled rotating spigot. To the Right of the main faucet is an ultra purified drinking water nozzle that has water that has been put through a full Acuva UV treatment to remove any possible remaining particles after ……….
……… it comes out of the main filtration which is handled by this triple set of progressive main filtration that all our potable water goes through.
We have eXcellent water pressure running about 65PSI thanks to this Kohree 7GPM pump. All the water system equipment is located in the externally accessed compartment that is midway along the DS.
On the PS of the Galley there is more countertop and our 2 burner induction cooktop that is eXtremely efficient and a joy to cook on. This cooktop fits snugly in the countertop cutout so it can be easily lifted out and plugged in outside when we want to cook out there.
The vertical extruded aluminium XAL on the Right here is the linear actuator for the PS Front corner of the Queen Bed lift system. Underneath both countertops it is all drawers as we find these much more efficient to use than cupboards and overall we have more than 20 drawers inside of Lance.
GALLEY DRAWERS:
I have always preferred dovetail joints for all drawers given their superior strength that stands up for decades of use and I think they look great too and so that’s what we went with for Lance. I was going to do this all myself but with almost a hundred dovetailed corners to do and SO many other jobs demanding my time and attention I decided to job this out. I found a fabulous company to work with called Barker Doors who offer a service using CNC (Computer Numeric Control) machines to custom cut all your drawers. I had all the drawers fully modeled in Fusion 360 so it was easy for me to send them these files with all the exact measurements I needed and they cut all the 5/8” Baltic Birch plywood to size for all the sides and the bottoms and then CNC cut all the dovetails. In the end this all worked out to cost less than I would have paid for just the Baltic Birch plywood and drawer slides so I was super happy with how this all worked out and I can recommend Barker Doors to anyone VERY strongly. They shipped all the pre-cut drawers to me as flatpacks like this so the whole shipment of all the drawers was not too large and they were all very well shrink wrapped and carefully boxed up so they arrived with no damage at all. They also offered a great prices on the the top quality Blum undermount ball bearing drawer slides I wanted so it all came as a single order which made my life easier.
Mounting more than 40 drawer slides to the XAL framework was very straightforward but time consuming to get them all exactly parallel and lined up. and some required a bit of Houdini moves to hold in place and tighten up. Next, I set up a little workbench on top of the PS Galley counter to assemble each drawer. Each set of dovetails only required a few drops of wood glue and they went together very well with two bar clamps and some taps with my little hammer to get the joints to fit together all the way. The dovetails were so precise that every drawer went together perfectly square and were solid as a rock. The Blum drawer slides required two slots in the bottom of each rear drawer side so I cut those out next and then I mounted to the Orange locking hardware to the bottom of the front corners. These are where the drawer slides clip into the drawer and make it very easy to lift out a drawer at any time. It’s a great system! Installing each drawer was now a simple process of pulling out each drawer slide………. ………… setting the pins in the rear of each drawer slide into the corresponding holes I had previously drilled and pushing them closed till they clicked in place. Et Voila! We’ve got drawers! Sad to say that I wasn’t able to get this done before we left on our big summer adventure so we REALLY appreciate having these now! I wanted all surfaces of these drawers to have a tough durable finish and decided to go with this two part Rubi Monocoat finish that you put on by hand with cloths rather than brush or spray. Hand rubbed finishes have always been my favorite and while this was a new one for me I was eXtremely pleased with the end result and the whole process of applying it. It was a bit laborious and a good workout but a very satisfying process for me. Difficult to see in photos but the Baltic Birch plywood came out with a glowing warm colour and a very tough finish that is also very easy to reapply in the future. To reduce the loss of usable space under the sinks I used these low profile P-traps which have turned out to work very well. and only required a small cut out on the rear of the two under sink drawers to clear nicely.
GALLEY CEILING & COB LED LIGHTING
Onwards and upwards I turned my attention to the ceiling of the Galley. It took a LOT of research to find the Goldilocks material for the ceiling but I finally found this White wood textured PVC trim molding material that checked all the boxes of light, easy to clean and attractive. It comes in 6” wide 8ft long planks and was very easy to work with. For lighting, I decided to use COB (Circuit on Board) LED strip lights which I set inside lengths of 20mm wide black aluminium U channel which I ran in between each of the White PVC ceiling planks. I like these newer COB strips for two reasons; they provide an uninterrupted line of light rather than individual points of light in the regular LED strips and they can be adjusted from about 2200K (very warm amber) up to 6500K (daylight white). In the past, SMD LED strips you have to chose a specific colour temp and they often have 60–120 LEDs per meter (≈1.5–3 LEDs per inch) whereas these COB lights have hundreds of micro‑LEDs tightly together, giving continuous light with no visible dots of light. Once I had the layout done and the strips of PVC and AL channel cut to length, the process went quite quickly. I could apply the construction adhesive to each plank and AL channel and press them up into place and then use my super handy cargo jacks and some scrap lengths of XAL to press these all up against the ceiling so they ended up flat and aligned. You can buy the COB LED lights in 20 meter rolls which you then cut to the lengths you want and solder three wires to the copper strips underlying the Yellow COB light strips. Takes a bit of practice to get these tight solder joints without any cross connections but all went pretty well after a few practice solders. Then I twist the wires to help reduce any electrical interference and slide a clear tube of heat shrink tubing over the joints and shrink them in place for a nice clean and protected connection.
Each of the LED strips have self adhesive on the back so you just peel off the protective wax layer and press these into the AL channel. I purchased the Black AL channel with frosted clip in covers so once I had the COB LED light strips glued in place and wired up ………… ……………. I could now press these clear covers in place. Here’s the result at about 6000k. These LED light strips are also fully dimmable so you can adjust both the colour temp from warm to cold white and from off to full almost daylight brightness.
We are very pleased with the end result.
Yet to come is the making of all the fronts to these drawers where I will get to use the fabulous 125 year old Cherry that my dear friends Colin, Rick and Sherry gifted us with but that probably won’t be until we get back here next year from our trip down to Baja so due stay tuned for all of THAT!
My sincere thanks for taking your valuable time to read these updates and join us on our adventures. Please leave your questions and comments in the Join the Discussion box below and hope to see you here again next week.
Hope all my American friends and family are wrapping up a great US Thanksgiving weekend. Christine has been back in Ft. Lauderdale for the past ten days enjoying some much needed Gramma time with our TEN year old Grandson Liam, seen here with his Dad Tim working on a new puzzle. As well as visiting dear friends of many years like Kathleen. Lucky me, while I can’t be there this time I often get to spend time with BOTH of these Gorgeous Galls. The pups and I have been holding down the fort here on Road Runner Ranch in Southern Nevada where the temps have started to drop and so Razz has taken to sunning himself on the solar panels for some extra warmth and seems like a good segue into today’s Lance progress update post on ……………………….. you guessed it; Solar Panels.
Living the nomadic and remote life that we always have, we are big fans having solar power be the primary source for all our daily electrical needs, which are quite extensive. On our boat Mobius we had factored solar panels into the design from the beginning and were able to have 16 large panels on three different roof surfaces on that boat such as these eight panels on the upper Pilot House roof. And here on Road Runner Ranch we have 18 solar panels in two banks, this one just set against one of our 40 foot shipping containers and the others you can see Razz laying on above. These keep our big EG4 Wall Mount 15kW battery charged up every day and running this through our EG4 6000XP Inverter/Charger provides all our electrical power for day to day life here. This is where the time I spent meticulously building Lance in a 3D model using Fusion 360 pays off. I could create a model for each of the different solar panels that I was considering and see how they would fit onto Lance’s roof and on the framing.
With much less surface area available for mounting solar panels on Lance’s rooftop I wanted to fit the maximum amount of solar output as possible and played around with lots of different solar panel models to get the Goldilocks combination that would fit. Over the years I have found it works best to design the overall electrical installation as a complete system because there are a lot of different pieces to this puzzle and they are all very interconnected not just electrically but also features and dependencies. I created 3D models for all of these components as well and you can see most of the components here in the Electrical Cabinet on the front Driver Side corner of Lance’s Hab/Box. There is a LOT to unpack here so I’ll cover the electrical system in a future post and get into all the details then for those interested.
After much deliberation and testing in the model, I decided to go with four SilFab 420 Watt QD panels which I purchased from Current Connected almost a year ago now. I was able to get these all installed this past May in time to help power us on our marathon maiden voyage with Lance driving out to Portland Maine and back this summer. For those interested you can see all the specs of these panels here and of course with the march of time since there would now be even higher output panels but we’ve still ended up with 1680 Watts of solar power and it has been more then enough to keep us fully powered all the time.
We do have additional sources of electrical power such as this 320 Amp 12V 3.8kW alternator on Lances Paccar/Cummins engine that can provide up to 4k of power anytime that engine is running. However on our summer test run I had not completed the installation of the Arco Zeus smart regulator so the alternator wasn’t working that whole trip and the solar kept our batteries filled the entire time so that was a pretty good testament as to how well the solar was working. I decided to use 10 foot lengths of galvanized Super Strut to mount the solar panels on Lance’s roof. I would have preferred to use aluminium Super Strut but the delivery times would not have been in time for me to get the solar panels mounted before our trip so I went with galvanized steel and they have worked out vey well. I laid them out as you see here, two lengths on each side and two down the middle. I added additional 4 foot lengths of Super Strut so that I would have a mounting system for the whole 14 foot length of Lance’s roof for mounting any additional items in the future. I kept the mounting very simple as well by cutting pieces off a length of 2” aluminium L bar, drilling two holes in each one for the mounting bolts, and using the very handy Super Strut M8 threaded inserts to bolt them solidly to the lengths of Super Strut. Quick, strong, simple; what’s not to like?!! I then made up the cables using extra UV rated cables, Red for the positive and Black for negative and crimping the MC4 twist lock connectors that are the most commonly used for solar panel wiring and which I’ve used a lot in previous projects so I have all the specialty tools, crimpers, etc. some of which you see here in the photo. To fasten the brackets to the solar panel frames themselves I inserted aluminium M6 threaded Riv-Nuts into holes I drilled into the vertical AL frame on the solar panel and then used this tool which compresses the threaded inserts and locks them to the frame. End result looks like this. One bolt vertically to fasten to the Super Strut and one horizontal to bolt into the solar panel frame.
For those wondering, I fastened the lengths of Super Strut to the roof using Loctite 8X PL Premium Fast Grab which is supposed to be 8 times stronger than traditional construction adhesives which I’ve used before. Probably overkill but you certainly don’t want solar panels flying off the roof when running down the highway at 70 miles an hour! To prevent any pooling of rainwater between the surfaces of the roof and the Super Strut I caulked all the edges with 3M marine sealant which I have LOTS of experience with on our previous boats. So everything fully sealed and eXtremely well fastened to the roof. Solar panel output drops off significantly with the rise in temperature of the panels, the irony of which isn’t lost on me, so I left this 4” gap where the two panels down each side meet up. This along with the 2+ inch space between the panels and the roof keeps them as well ventilated as possible and the efficiency of their output was very good even in the 40C/105F days we had several times on the trip AND while I was installing these panels! Talk about a cat on a hot tin roof! Ouch! To make it a bit easier to run the cables AND give me a wee bit of shade, I was able to remove the inner brackets and use the outer ones like a hinge and prop up one lengthwise pair of panels while I ran the cables. I ran the eight cables for all four solar panels to converge at this point on the front DS corner as this puts it directly overtop of the Electrical Cabinet below where they need to go and thus provides the shortest cable run for least voltage drop. I drilled the only hole in the roof for this but it was a BIG one as you can see and then I used more 3M 5200 to seal a short length of 2” PVC pipe as a safe conduit through the roof for these and all other cables in the future. The red square you see on the bottom is 3M VHB Very High Bond two sided tape which is a fabulous product for gluing almost anything to anything and it never comes off. PVC box now glued down to the roof over that PVC pipe and the cables run non stop down into the Electrical Compartment below.
Each solar panel needs to have a shut off so I used these DIN rail mini circuit breakers to do that and provide over current protection.
I use threaded glands, the black things you see here and above, to give each cable a watertight entry into all junction boxes. This is what it looked like inside the Electrical Compartment where the cables pass through. The output of solar panels is a much higher voltage than the batteries and needs to be regulated to different charging stages to properly charge the big LiFePO4 Lithium EG4 batteries in Lance so the output of the solar panels goes through a MPPT controller which looks after all of this. Although it isn’t common, the most efficient setup is to have a dedicated MPPT controller for each panel and so that’s how I’ve always built our solar systems. Those are the four Victron Blue boxes you see on the upper Right here. It’s a bit of electrical spaghetti and took a bit of time to route and connect all these cables but keeps all the wiring very well contained in the wire ducts like the one running vertically up the far Right side and will have a cap that snaps onto those fingers you see here. Final cabling is to take the output from each MPPT controller and connect them to the main 12VDC electrical bus bars which are the silver coloured bars you see running up on the far Right here. If you look closely you can see two Red and two Black cables connected together at the top and then the other four below so now all the power from the solar panels is connected into the 12VDC electrical circuit.
And here’s what Lance’s 1680 Watts of solar roof looks like.
The extra length of Super Strut has already come in handy for my temporary for now mounting of our Starlink dish and the 4” PVC tube running down the middle for storing long lengths of material I like to have for ongoing projects while we’re on the road. Go ahead and tell me you’re surprised?!?!
Did I mention that we LIKE solar panels???
And that wraps it up for this weeks progress update, hope it was informative and enjoyable and let me know what you think in the “Join the Discussion” box below.
As this recent holiday has reminded me I am indeed one eXtremely fortunate fellow with SO much to be thankful for, not the least of which is YOU, for the time you choose to take out of your busy schedule to read and comment here and join us on this latest adventure of the Ambo Nomads.
I’ll be back again next week with the next installment and hope you’ll join me again for that.
Ciao for now,
Wayne and “Sunny Boy” as he tells me he now likes to be called.
I always liked the John Lennon line from his Beautiful Boy song in 1980 that “Life is what happens while you are busy making other plans” and that’s a good summary since my last update here. It has been a very busy and fun six weeks with no shortage of projects, trips and milestones but not so much time for updates so thanks for your patience. Two birthdays in January, one for me on the 23rd and daughter Lia on the 14th. So we decided to make the relatively quick drive, less than 4 hours, over to the LA area to surprise Lia on her milestone Four Oh!birthday by delivering some some B’day flowers, champagne and hugs in person. As a bonus we went back for a week to see Brynn’s Talent Show at her school and then got to be full time Gramma and Grampa for the weekend while Brian & Lia had a fully unsupervised weekend away for Valentine’s Day. We continue to work away at getting things setup here on “Road Runner Ranch” and this arial shot from Christine’s drone video that you might have seen in the previous post, shows how we are setup so far. The 40’ shipping container above on the left is what I’m setting up for my workshop with Lance parked right beside. The matching container on the Right is what we’re using for storage and is close to our 25’ travel trailer that continues to provide a very comfy home for us and the two pups for now.
We recently got a good deal what they refer to as a “garage fridge” so we’ve now got that set up inside this container to expand the fridge and freezer space that is built into the trailer and keeps us well stocked in food supplies. This panorama shot (click to enlarge any photo) will help you get a sense of the setting we’ve got for our little sanctuary here and might help some of you make a bit more sense of why this is such a Goldilocks location for us.
Best news for me and many of you who I know have been waiting, is that I’m back to working on converting “Lance” our 2017 Kenworth ex medium duty ambulance into our eXploration RV. I’ve picked up where I left off building all the cabinetry framing using lengths of eXtruded ALuminium which I’ll abbreviate as XAL. Looking forward from about mid way inside Lance’s “Happitat” the blank wall on the left is the front wall with the cab on the other side and the main entry door that is on the passenger side PS in the right corner. I’ve put in a scrap of 3/4”/20mm plywood to create a desk for myself on what will eventually become one of the two galley countertops with a larger one yet to be framed on the opposite left or driver side DS. The XAL you see on the ceiling is where the forward side of the lifting Queen bed will go with a large L shaped settee below. Here is a sample of a length of the XAL with several different corner brackets that bolt into the T track grooves in the XAL which turn this into a giant adult version of the Erector sets I used to love playing with as a young boy, long before many of you were born! I’m working my way somewhat counter clockwise around the Happitat walls so my next focus was the XAL framing you see now in the front right PS corner. The Blue poles you see ratcheting cargo support bars that have proved indispensable to me for holding things in place as I build. This full height cabinet will have our fridge/freezer mounted inside the large opening you see here with lots of storage in the spaces above and below.
Shower will be in the middle on the left here and the head/toile over in the far left DS corner that I’ll move onto next. This front DS front corner is a bit more complex as the large vertical exterior access cabinet is also in this corner and it is where I’ll be installing Lance’s whole electrical system with three large lithium batteries on the very bottom and then all the other components such as 12VDC to 120/240VAC inverters, battery chargers, and much more mounted this exterior locker.
Here on the inside is where I now need to finish the XAL framework above the battery frames I’ve built to support the three big batteries. This will give you a sense of the size and shape of the server rack style lithium LiFePO4 batteries that will provide all the 12VDC and 120/240VAC electrical power in Lance. For those interested in the details, this shot the label on one of the three batteries will give you all the numbers.
While 45Kg/90 lbs might sound like a lot when you consider that each one of these provides 5120 WattHours (400Ah @ 12.8VDC) the power density is pretty amazing. Having three of these connected in parallel will provide a total of 15.36Kwh (1200Ah @ 12.8VDC) which will will be more than enough to give us all the power we need for our all electric cooking appliances such as induction cooktop, coffee makers, toaster oven, microwave as well as powering our mini split Air Conditioner. As with all of this build, I had created very accurate 3D models using Fusion 360 of all the XAL framing and each of the components such as this Joolca separating toilet and the EG4 batteries and these have served me very well throughout the build.
I knew that the batteries were going to be a very close fit and I had built the framing for them back when we were in Klamath falls but now was the moment of truth to see if they actually fit?!! The “ears” of the server rack batteries were a few millimeters wider than the opening of the door frame so it took a bit of wiggling them in at an angle and some gentle persuasion, ……..
……. but they fit in snug as a bug in a rug as you can see here and put a big grin on my face.
These server rack style of battery are very safe and easy to work with as they have both an On/Off switch (silver circle upper right) that turns the BMS (Battery Management System) on/off as well as the high amp double pole high amp circuit breaker (White/Blue on bottom left) so I could keep bot of those turned Off and ensure that there was never any danger of a short to the terminals while I was wrestling them in place. Locating the batteries in this front DS location was ideal as it kept the weight down low, centered and on the opposite side from the fuel tank and also enables me to keep all the electrical system components in this one externally accessible locker.
However it did require me to raise the floor and design around them on the inside as you can see here. After playing around with the 3D model for some time, I ended up making this raised area inside be just the right height for the floor under the Joolca Gotta Go separating toilet. With the shower area in the center area the whole bathroom space becomes feels very large and open both when using it as a shower and when seated on the throne. I had my Beautiful Bride check it all out in person this morning and got the two thumbs up so the framing progress can now continue. I also checked in with these two scallywags, Razz on the left, Zoe on the right, and got their approval as well so I’m all systems GO now.
So I will continue to work my way around the DS corner as I move onto framing out the Galley/Kitchen area that runs down the rest of the Drivers Side and you’ll see that in the next update. We continue to get sunsets like this almost every evening and sunrises are pretty spectacular as well so we continue to enjoy our new location a bit more each day. That’s a wrap for this update and I’ll do my best to post the next one much sooner and try to get back to doing one every Sunday as long as “life” doesn’t interfere!
Hope you enjoyed the update and thanks to all who persevered to this point. Be sure to add all your questions and comments in the “Join the discussion” box below and hope you’ll be back for more in the next update.
As predicted when I left off in the last update here, it has been a VERY BUSY time the past month for us but we’ve made the move and are now settling into our new Southern Home Base down near Searchlight Nevada.
There are some photos and details about our new 10 acre property in that PREVIOUS POST back on Dec. 8th so you can check that out if you’d like and I’ll just pick up from where we left off.
BONUS: Be sure to read to the end to see the bonus video that Drone Captain Christine put together.
Our son Skyler flew down from Vancouver BC on the 23rd of December to join us for the holidays in Klamath Falls and he was a HUGE help getting all my tools, equipment, materials and such packed up from the workshop I’d set up in Klamath Falls. Along with our personal belongings and food we managed to get everything loaded into Lance and the beds of the two pickup trucks we now find ourselves with.
We were a bit sad to leave as we had really enjoyed our time getting to know Klamath Falls and the surrounding area of southern Oregon. This is the parting shot just after noon on Boxing Day (Dec 26th) as we bid a very fond adieu to what had worked out to be a great home and workshop and hit the road for the almost 700 mile drive down to our new Southern Home Base just north of Searchlight NV. We broke the trip up into two legs with an overnight stop in Fallon Nevada and it turned out to be a great drive with clear dry roads after we got about a hundred miles south of Klamath Falls and enjoyed the ever increasing temperatures as the miles rolled by. We arrived at the property late in the afternoon of the 27th with big smiles for all three drivers and both pups. And just in time to catch this beautiful sunset which we’ve now discovered is most every night here.
Christine has been getting her drone flying skills dusted off and this shot she grabbed a few days ago from up above the spot we’re setting up to live on for the next few months will give you an idea of the layout. Those two big white rectangles are 40 foot “High Cube” (9’6” high) shipping containers that came with the property along with a lot of great items inside that you’ll soon see. The other white rectangle is the 2012 25 foot travel trailer that will be home for us for now.
** See the Bonus drone video at the end. As Skyler and I unloaded the crates of our belongings and coolers of food, Christine got to work storing it all away and organizing our new home. As sharp eyes might notice, she even baked a loaf of banana bread! Looking aft in the trailer you can see that we’ve got everything we need with a nice U shaped settee and an adjacent full bathroom & shower. Then a separate bedroom in the rear with a Queen bed and even an office for Christine to work at just out of sight in the rear left corner here at the foot of the bed. And check out our views out the windows! This floorplan helps to show how the bedroom & settee are in a slide out section along the right side of the trailer that really helps open up the space.
Keeping in mind that we are both used to living full time in boats, for us this is HUGE!
Skyler started unloading all the crates and materials from Lance and I started to figure out where to put them for now in the two containers. The one you see here on the Left will be my workshop area and the other one out of site in this photo over on the far Right closer to the trailer provides storage for everything else AND houses all our fresh water and electrical power equipment that allows us to live 100% off grid. Could not have been a better present than all the time we got with Skyler and all the hard work he so cheerfully gifted us with to make this latest transition of the Nauti Nomadic Grandparents so memorable. Thanks Sky!
It will take me awhile to build workbenches and storage racks but for now all my tools and equipment are very safely stored away inside the two containers.
Part of what made this property such a Goldilocks just right find for us was that one of the things inside the containers was sixteen 305 Watt solar panels and so Skyler and I got to work setting those up in two different locations to try out for now. Eight of those solar panels we propped up against the wall of the container as you can see here which made it a short run for the power cables to go into the MPPT controller inside. Of course the HIGHEST priority was getting the new Puppy Play Pen set up for Zoe and Razz to enjoy. The other eight solar panels we propped up against the south facing side of the trailer to try out that orientation as I monitor the daily production to see what generates the most power to keep our big new battery bank fully charged every day.
All very rough and tentative till we live with all this for awhile and decide best location on the acreage to build on and then I will build proper ground mount racks for all these and perhaps more solar panels. In that previous post you may recall seeing this pallet full of boxes that had arrived at the Klamath Falls workshop which contained the other two key components of our off grid power system. this 15 kWh 54 Volt upright EG4 lithium battery and ………. …….. this EG4 6000XP all in one MPPT solar charge controller, inverter charger.
The battery weighs a svelte 128kg/282 lbs. but Skyler and were able to get it wrestled out of Lance and into the container and get the 6000XP mounted above it and all secured to the steel walls of the container. These two smaller vertical boxes I mounted on on the side at the mid point are the isolation switches and circuit breakers for the high voltage power coming in on the Red and Black wires you see here which come from each of the two strings of solar panels (8 panels in each). We soon had everything wired up and in this shot I’m busy configuring all the settings before turning it on for the first time. Just amazing how far these kinds of off grid systems have come and we were able to go from no power at all when we arrived to having a full 240VAC split phase power system in less than one day. We had about 190L/50 USG of fresh water that I had filled up the trailer’s water tank with on my way bringing it back from where we bought it in Tucson so we had plenty of potable water for drinking, cooking and showers the first few days but now time for a more full time setup and another part of what made this property such a great find for us. These four 1250L/330USG IBC Totes as they are called (Interim Bulk Containers) also came with the property along with a fifth empty one that we’ll use in the future to bring more fresh water from the town water system in Searchlight that is just a few miles away. The pumps you see at the bottom here are now all set up to provide pressurized fresh water to a tap on the outside of the container and a hose from there to the trailer provides all the fresh water we need for day to day living.
It will take us a bit longer to get everything setup and be able to get back to working on books and Lance but we’re off to a great start and new year.
Can’t be all work and no play so in the midst of all this we also took time to celebrate the new year in our new home base. Christine and I adopted giving “experiences” rather than “stuff” to each other for gifts and this year I got us three tickets to go see the “Immersed in Van Gogh” experience in Las Vegas on New Year’s Eve which is less than an hour’s drive north from our property.
Then Christine had rented a boat for the three of us to go out on Lake Mohave for New Year’s Day. This shot is looking about due East from our place and off in the distance about center (click to expand any photo) you can see the Colorado River flowing South. Hoover/Boulder Dam is to the North and Davis Dam to the South which creates Lake Mohave in between. It only takes about 15 minutes to drive from our place to the marina on Lake Mohave. I will leave you with this shot of what our humble new abode is looking like with yet another super sunset that Christine loves to photograph.
I know many of you are shaking your heads and wondering what drew us here but perhaps these two days with New Years eve in Las Vegas and then New Year’s Day out on the lake both being minutes away from our otherwise eXtremely remote spot might help you understand a wee bit better what makes this such a Goldilocks place for us.
Location, location, location right??!!
BONUS VIDEO:
As promised, here is a short video that Christine has put together as she dusts off her drone flying skills for this quick flyover what we are thinking of calling “RoadRunner Ranch”. Although we have not yet spotted one here yet I hope this quick flyover part of our 10 acres will help you visualize this location and maybe help you see what we see. In any case do enjoy and thanks Captain Christine!
Hope all of you have 2025 off to a great start as well and I’m looking forward to getting back to regular updates in the next few weeks as I get my new workshop up and running and get back to working Lance. Thanks for joining us on yet another adventure and please leave any questions or comments in the “Join the Discussion” box below.
Yet another week without a lot of visible progress to show you, but all of our various shippers, USPS, FedEx and UPS were certainly busy as the pallets full of boxes with more and more the equipment we’ve ordered for transforming Lance into our new home on wheels continued to arrive here at our workshop/home in Klamath Falls.
I won’t be able to install it all right away but we are hoping to move down to Nevada at the end of December and so we are trying to maximize the benefit of having no sales tax for the remainder of our time here in Oregon. With the amount of equipment required to build a full self sufficient XRV, this really starts to add up to a significant savings and given the size of those bills, we take all the help we can get! Here is the most recent set of pallets that arrived on Friday. These two pallets are from Current Connected with four 420 Watt solar panels on the Left and then the Victron inverter/chargers, MPPT controllers and EG4 batteries on the Right. These are a bit fragile but they all arrived in perfect condition. I unboxed one of the EG4 12V 400Ah server rack batteries to check them out a bit closer and to get the exact dimensions so I can complete the XAL eXtruded ALuminium racks I’ve installed in Lance. There are three of these monster batteries that I’ll wire up in parallel to create our 12V 1200Ah House Battery bank which gives us a whopping 15.4kW of overall capacity. Even though we have gone mostly electric with all our systems other than diesel for our heating, our daily requirement will be much less than this but I’ve gone to this capacity so that we can stay remote for weeks at a time even with long periods of cloudy days with low solar output. These two Amazon boxes contain the new sink and induction cooktop for our new Galley aka Kitchen in Lance. This is the Empava 120V 1800 Watt two burner induction cooktop that Christine chose. It will be built into the countertop but can also be removed and taken outside to create our outdoor kitchen in hotter weather. Christine set this up here in the house and made dinner with it two nights ago and she gives it an enthusiastic two thumbs up! We both much prefer induction cooking after our experiences with it on Mobius. This is the 28 inch dual SS sink. It is a generous 245mm/10” deep as we both prefer big deep sinks. This one has some great features that extend its usefulness such as this wooden cutting board and a strainer that slide back and forth in the groove you can see at the top and bottom. There is also a drying rack for dishes that rolls up out of the way when not needed. While there isn’t too much visible progress I can show you it isn’t for lack of hours and I have been busy with Fusion 360 working through the details in the 3D models I’m building for this project. Here is a quick screen grab that I hope helps you visualize the interior layout. Double sink in the Drivers Side Galley countertop up top and the induction cooktop on the Passenger Side. Dinette is at the rear with lift bed above added in and then the Fridge/Freezer and AirCon in the PS front corner on the far Right here with the shower in the center and the Head on the Left behind the partially open red door. The one bit of visible progress I can show you from this week is that I installed this finished vinyl flooring that I showed you last week.
Pretty straightforward process; peeled off the protective plastic layer with the blue arrows and then starting laying down the 8 inch wide click-lock planks. It is not the recommended practice, but I’ve decided to install this finished flooring first and then put in the framing for all the cabinetry as this will create a much cleaner install of the XAL eXtruded ALuminium framing. We used this same type of industrial grade LVT planking in Möbius and were eXtremely happy with it so we stayed with what we know works. We are thinking of using a darker wood for the cabinetry, Cherry or Walnut and so wanted to keep the floor a lighter colour. If you look closely (click to expand any photo) you can see there is a wee bit of wood grain in this flooring which also provides a very safe non-slip surface that cleans up very well and is impervious to any spills or dropping of heavy objects. Also very “dog friendly”!
Razz and Zoe have been eXtremely busy as well as you can see from this shot of what is at my feet as I type! And that wraps up another week and ………. unbelievably ……… another month!
Thanks for taking the time to follow along with us on this latest journey of the Nauti Nomadic Grandparents and be sure to leave your questions and comments in the “Join the Discussion” box below.
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