An Example of Building a Camper / RV for Cycling Enthusiasts
Translated by Total-Energo LLC specifically for motorhome (and cycling) enthusiasts in Ukraine, as an example of how a great project can be accomplished remotely if the customer has experience with electrical equipment.
A couple dreams, designs, and builds a cycling base camp
This week let's hear from cyclists Russell and Kim Gillard from Nebraska, USA, who made their camper dream a reality, allowing them to take their hobby further and relax at the end of the day in the perfect mobile environment. Russell explains...
Outdoor Adventures
My wife Kim and I are avid road cyclists. We usually ride about 2,500 miles a year, mostly in Nebraska where we live, and also in Colorado. A few years ago, we decided it would be great to have some sort of camper to extend our cycling trips beyond just day rides.
We started looking at campers but didn't like how cheaply they were made. We also didn't have a vehicle to tow a camper, which would mean buying an expensive truck.
We considered converting a school bus but ultimately decided to convert an ambulance. After all, we both work in the medical field and know the quality of these vehicles, and we liked the fact that they are generally very well maintained.
The First Steps...
We spent about 4 months looking for the right vehicle and eventually purchased a medium-duty Freightliner ambulance from a fire department in Chambersburg, Pennsylvania. This is the mother of all ambulances. It was a 2014 model, and it only had 78,000 miles on it.
I was discussing this project with one of my patients, who agreed to fly out and drive it back to us here in Nebraska.
Our first task was to replace all 6 tires, balance the wheels, and get an alignment. We also checked the brakes.
Next was a trip to Cummins for engine service. We asked Cummins to increase both horsepower and torque via a software tune without voiding any warranties. They also removed the electronic speed limiter, raising it to 75 mph. The Allison transmission on this vehicle was a 5-speed, but the 6th gear was locked out. There is a company that reprograms the transmission control module, making the 6th gear available and improving fuel economy.
Energy System and Victron Energy
When it came to the electrical system, we checked the internet and found that many people were using equipment from a Dutch company called Victron Energy.
Our Goals for the Vehicle's Off-Grid Power System
A quick internet search revealed that there is a Victron Energy representative named Mark Stevens, whose company Off-Grid Solutions is located in Chadron, Nebraska, practically out our back door! We arranged with Mark for the first of several Zoom meetings to discuss our goals for the vehicle, which included:
☀️ Maximum Solar Energy Usage Integrating roof-mounted solar panels for autonomy even in remote locations.
🔋 Powerful Battery System A battery bank that allows us to wild camp for several days even when it's cloudy.
❄️ Energy-Efficient Climate Control Energy-efficient heating and cooling for the vehicle. We didn't want to use any of the traditional roof units found on most RVs.
🌐 Reliable Internet Access Reliable high-speed internet access even when camping remotely.
📱 Remote Control Remote access to the power system from a computer or phone.
Bringing It All Together
Mark and I worked on the system design for about 3 months. We had Zoom meetings and then exchanged schematics and design ideas via email. Here is the final design.
Once the project was finalized, Mark ordered the equipment, and I drove out to him in the ambulance to pick it all up. You can fit a lot of stuff in an ambulance! I have a background in electrical engineering and am an amateur radio enthusiast. I am also quite proficient with AutoCAD. While I was waiting for the equipment, I laid out the electrical cabinet and battery compartment for the ambulance and created an AutoCAD rendering of what it would look like.
By the way, if you are not an AutoCAD fan, the design department at Total-Energo can help you arrange the equipment throughout your motorhome so that it is compact and convenient.
Next, I started mounting the devices and wiring them up.
What's On Board?
The Freightliner installation consists of:
A powerful battery bank for off-grid power in your motorhome.
This is a battery management system specifically designed for Victron Energy lithium batteries.
A modular DC busbar and distribution system with monitored MEGA-fuses.
Harvesting solar energy to charge the batteries.
The charge controller maximizes and manages solar energy collection.
Provides AC power for household appliances.
For alternator charging. Allows 12V devices to run directly from the 24V battery bank.
Charges the starter battery from the grid in harsh environments.
Monitors power input/output to provide state of charge data (and much more...).
Ensures the battery is never accidentally drained by household electrical loads.
The Interior of Our Dreams
Next, we sent the ambulance to Colorado Adventure Vans in Golden, Colorado. John and his team worked closely with Kim and me to design the interior of our dreams, including:
❄️ Isotherm marine refrigerator/freezer
🛏️ Fold-out queen-size bed
🚿 Stand-up shower, accessible from the outside
🚽 Wrappon Green toilet, we didn't want to mess with black water tanks
🔥 Diesel water heater, which also heats the ambulance
❄️ Pioneer mini-split for heating and cooling
🍳 Induction cooktop for heating up soups, etc.
🌐 StarLink router installation
🪵 Corian countertops
By the way, the specialists at Total-Energo LLC will gladly help with manufacturing furniture and installing it along with additional options in your motorhome. Contact us for a consultation!
This is a three-season camper. 2023 was our first full season with it. We spent 24 days camping and absolutely loved it.
A few more things to note. We replaced the front seats with new ones. We also replaced the front center console with a custom-made one by Colorado Adventure Vans, using the same Corian as in the back.
We left most of the ambulance wiring intact. The lights, sirens, PA system — everything works. We have 2 One Up bike racks mounted vertically on the back.
I designed and fabricated a roof rack out of 80/20 extruded aluminum for the ambulance. It holds our solar panels, an awning, and the StarLink antenna.
What's Next?
Victron Energy representative Mark Stevens told me separately how impressed he was with Russell's wiring and equipment layout – which makes sense given that, in addition to his medical career, Russell holds a bachelor's degree in electrical engineering! Rusty and his family liked the Victron system so much that we are working on another project for their home, which includes two EV chargers as part of the load!
How this example is useful for the Ukrainian market
At the very least, it shows that if you have the desire and interest, with high-quality support from certified Victron Energy specialists, you can complete such a project yourself. Moreover, there are already many examples of similar solutions in Ukraine that have been actively used for several years. The clients amazed us with their installation capabilities; it was a true team project:
🛠️ Total-Energo LLC provided:
✓ Project development
✓ 3D visualization
✓ Wiring diagrams
✓ 100% Bill of Materials (BOM)
✓ Supply of main equipment
✓ Information support during installation
✓ Commissioning support
👤 The customer independently:
✓ Installed the equipment
✓ Performed the wiring connections
✓ Carried out all necessary steps during the commissioning process
✓ Tested the system's performance in all operating modes
Want to implement a similar project?
Yes, at first glance, Victron Energy systems may seem complicated, but once you start working with them, you enjoy the process itself because it is professional equipment that exudes intelligence and reliability. It's a pleasure to work with, and even more enjoyable to use on vacation!
