187 replies to this topic

[Hodakaguy]

Installing the Solar Controller and Powerlet Connection.

 

I'm getting ready to install the solar panels on the roof and it's time to get the Solar charge controller installed.  I'm going with a BlueSky Solar Boost 3000i MPPT Controller, I've used this controller in my Syncro and it worked great so decided to stick with what works :-)

 

The factory provides a cut out for their controller right above the heater.

 

 

Removing the cover on the controller cutout.

 

 

 

 

The factory pre-wired the camper for a Solar Controller so install will be simple.  The wiring is tucked up above the heater unit.

 

 

 

The 3000i charge controller

 

 

 

The factory cut out is a little small for this controller so some cutting is in order.

 

 

Covered the heater unit with a garbage bag to keep the saw dust out of the important bits.

 

 

Front cut out and here I've marked a notch that needs to be cut for the rear of the unit.

 

 

 

 

Test fitting the controller.

 

 

 

Battery wiring is tucked against the far wall behind the batteries.

 

 

All the wires were marked from the factory making it easy to identify, I went ahead and verified everything with a meter before wiring everything up just to make sure.

 

 

I used Marine grade heat shrink crimps on all connection.  I didn't get any pics but there is a fuse holder wired into the battery area.

 

 

Connecting the controller.  I'll be fabricating a cover for the rear of the controller soon.

 

 

 

 

Continued Below....

[Hodakaguy]

Time to install the power connection for the ARB Fridge.  I absolutely hate US cigarette lighter connections, they always get loose and your constantly pushing the plug back in.  I cut the factory cigarette lighter plug off the fridge harness and wired in a Powerlet connector instead, I'll keep the cut off end and make an adapter so I can also connect to a Cig lighter if needed.  Powerlet connectors are great, they snap in place and won't get loose as you travel down the road.

 

Here is the fridge harness with the new Powerlet end installed.

 

 

Powerlet socket that will be installed in the camper.  The depth of the socket isn't deep enough to pass through the wood on the camper so an adapter will need to be fabricated.

 

 

Fabricating the Powerlet adapter from a scrap piece of aluminum.

 

 

Holes drilled and socket test fit.

 

 

 

I drilled a hole in the heater unit just above the heater to install the Powerlet.  The hole needed to be slightly bigger to clear the nut on the back of the socket.

 

 

Wiring completed for the Powerlet socket.

 

 

Controller and Powerlet installed, I painted the adapter black.  Looks factory :-)

 

 

 

 

Hodakaguy

[Casa Escarlata Robles Too]

Question,when you cut the plug from the wire how do you determine the + and - ?

Frank

[Hodakaguy]

Question,when you cut the plug from the wire how do you determine the + and - ?
Frank

Before I cut the plug off I used a multi meter to check continuity between the tip of the factory cigarette plug and the fridge plug end so I can determine which one was hot and which one was ground. I then marked the plug on each side and then double checked with the meter as I wired the new connector.

Hodakaguy

[Rafter C]

Howdy Tom,

 

Loving your build up here on both the truck and camper. As usual, attention to detail and precision. I remember that from your days over on Adventure Rider. I'm one of your customers for an Acerbis tank bracket for my trusty XR650R. Still going strong. I'm also an ATC Cougar owner. Nice to combine the interests into one. Tow the trailer with the bikes, sleep over in the camper. Keep up the good work...

[CougarCouple]

Hello Hodakaguy

Real clean work you and you pop's do.

Russ

[Hodakaguy]

Howdy Tom,

 

Loving your build up here on both the truck and camper. As usual, attention to detail and precision. I remember that from your days over on Adventure Rider. I'm one of your customers for an Acerbis tank bracket for my trusty XR650R. Still going strong. I'm also an ATC Cougar owner. Nice to combine the interests into one. Tow the trailer with the bikes, sleep over in the camper. Keep up the good work...

 

 

Thanks, glad the brace is still going strong!  I'm still making the braces :-).  The FWC's work great for dirt biking trips!

 

Hodakaguy

[Hodakaguy]

Hello Hodakaguy

Real clean work you and you pop's do.

Russ

 

 

Thanks, we enjoy it :-)

 

Hodakaguy

[Hodakaguy]

Installed the fridge to run it for a couple days and test the battery system, should be able to run for several days with no external power with the dual batt system.  I'll be installing 240W of solar soon then battery power shouldn't be a issue.

 

 

With the top down on the camper there is still plenty of room to get into the fridge at rest stops ect without having to pop the top. I'll be installing mounting straps to keep the fridge secure in this location.

 

 

Next up fabricate a rear guard for the solar charge controller to protect it from items stored inside the cabinet.

Starting out with a piece of aluminum plate.

 

 

Cutting the piece down to rough size.

 

 

 

Corners trimmed.

 

 

Marking out the locations for the air vent holes.

 

 

Air holes drilled and beveled.

 

 

Using the finger brake to bend up the guard

 

 

 

 

Fabricating some hidden mount tabs from some scrap pieces of stainless.

 

 

 

 

Factory trim pieces cut down to size and re-installed.

 

 

Test fitting the guard in place.

 

 

 

Guard painted and installed in place.  Should keep the controller well protected.

 

 

 

 

Hodakaguy

[Hodakaguy]

Lots of progress today......Picture Heavy!

 

Started this morning by installing a 110V NOCO power plug on the side of the camper.  This port will connect to a IOTA 15A AGM onboard charger (to be installed soon).

 

The NOCO power port

 

 

I'll be sealing the port to the camper with Sikaflex 221....Good stuff.

 

 

The port will be going into the battery compartment just aft of the vent.

 

 

Pilot hole drilled....committed now lol.

 

 

2" hole drilled.

 

 

And power port installed and sealed.

 

 

 

 

 

Next up install the Hypertech inline speedometer calibrator.  This is a small unit that goes behind the instrument cluster and allows you to correct the speedometer for larger tires.  Drives me crazy seeing the speedo off from the GPS :-)

The Hypertech unit.

 

 

Installing the unit.  I routed the USB cable down under the dash and stored it up out of the way, if I need to make tweaks to the calibrator to get the speedo spot on with the GPS I can just plug in the computer and easily make the changes without having to remove the dash again.

 

 

 

 

 

Time to install the new SSO (Sothern Style Offroad) Hybrid bumper.   Here I've installed the Baja Designs 30' light bar and the winch fairlead.

 

 

Installing the synthetic rope on the Warn Zeon 10S.  The anchor setup to the spool is pretty slick.

 

 

 

 

We connected the winch to temporary power and with my dad pulling on the cable spooled it in.  Once the assembly is on the truck we will properly tension the cable.

 

 

Mounted on the bumper.

 

 

Continued Below.....