Update on our Tiffin Allegro Open Road 32SA

This page will be a running record of the changes and upgrades we have made to our Tiffin Allegro Open Road 32SA.  They are in roughly reverse order – most recent first.  We expect you’ll never want or need to do all of these things, but I expect you will find some of them quite useful.  Current update is 12/21

On 4/23 I released my list of 100 updates and additions to our Tiffin Open Road. 

These next two items aren’t really Tiffin specific – they could happen with any RV manufacturer.  I include them here because they might not be so obvious.

Bathroom Sink Drain

Our bathroom sink always drained slow.  I think I knew it wasn’t adjusted right, but I just never got around to working on it.  After all, we just mostly brushed our teeth and washed our hands.  Well, eventually it got so slow that I just had to do something with it.  I reached underneath and unscrewed the lever entry that raises and lowers the stopper.  I then pulled the stopper out – which had a huge accumulation of gunk on it.  Apparently, as the stopper never raised very far, lots of soap settled out onto the stopper and made the situation worse.  In the end, the problem was that the stopper had been installed backward.  The tab at the bottom of the stopper is offset and that offset should be toward the front of the sink, away from the stopper actuator.  This ensures the most movement of the stopper, thus allowing water to flow out of the sink at a reasonable speed.  Just a minor misstep at the factory.

UPDATE:  The “chrome” drain ring has started to rust, leaving a nice rust stain in the bottom of the sink.  I purchased a new drain with lever/plug and went to install it.  Ususally, these go pretty simply.  Just remove the old one, clean up any sealing surfaces and install the new one with some plumbers putty where it meets the sink.  Thus I did and of course it all leaked.  The nut that you screw up from underneath has a big rubber seal that is supposed to seal to the bottom of the sink – which had a nick in it – so more plumbers putty needed to supplement the seal.  Also – I had to remove the J-trap to get everything in position – and its connection to the drain pipe leaked too.  The original installers had added plumbers putty there too, which I had to clean off and add my own.  Never before have I had to go through all that to replace a drain. – Update – the new drain also rusted. I found a drain that used a solid, full chrome cover drain.  Hopefully this one will last more than a few months.

Black Tank Flush

Black tank flush sprayer
Black tank flush sprayer

A bit more of a confusing and problematic issue.  Last year, our black tank flush became plugged.  Over the months before, we had done some dry camping.  That meant, at times, having to move the RV with a partly full tank to a dump station and not always having a flush hose available.  We were going through Red Bay for another reason, so we had them look at it.  They chose to just replace the sprayer.  It was difficult to get out because the bottom screw was actually below the top of the freshwater tank, but the tech managed to get it out.  Looking at the sprayer, I thought – maybe it should be flipped so the flat side is down, making it easier to install/remove.  I convinced the tech to do that, which was WRONG!  The sprayer has holes at the end and bottom – so now it was spraying the top of the tank AND anything that splashed into the sprayer holes tended to stay.  Six months later, it has hard plugged again.  I pulled it out, cleaned thoroughly, and re-opened the plugged holes.  Then I realized the problem.  The sprayer had been installed in the WRONG place.  The flat side is intended to line up with the top of the tank.  Mine was over 1.25 inches below the tank.  While that doesn’t seem to be a lot, the tank is only 7″ tall on this end, so that is a full third down.  Our tank had never been more than 2/3 full according to the tank monitors (yes, doesn’t mean a lot), but with the sprayer this low there were certainly times when it was soaking, not just getting some splashes due to moving the RV.    When I can find the appropriate materials, I’ll be patching over this hole and moving the sprayer up and over just a bit to the top of the tank. UPDATE: haven’t moved it yet, but I have pulled and cleaned out the holes twice….21

Forgetless flushing

Dead man flush valveWhen flushing “they” say to always leave the black tank valve open.  That’s so you don’t overfill the tank  Many people say its ok to close the valve so long as you only let it run for a couple of minutes; the idea being, it will drain better if its got a few inches of water in it when you open the valve.  The problem with this method is interruptions.  The neighbor walks over and starts a conversation.  Your kid starts to scream bloody murder on the other side of the RV.  Bigfoot walks by.  Whatever the reason, you forget to turn off the flush or open the valve.  Your tank fills up and starts to turn into a round tank in a square hole.  Dirty water backs up in or under your toilet and if pressure gets high enough, it starts spilling out on your roof.  I’ve seen a black tank (not mine) blow out the bottom of a trailer as well as flooding the inside.  So I installed a “dead man valve” on my rig.  I have to hold it open to flush.  I even put a different quick connect on (no other hose has one that will fit), so if someone else ends up dumping my tanks they are at least “encouraged” to use the valve. In case you think this would never happen, it did happen to us when I had a medical issue, my wife and a son ended up processing the tanks when I was out of commission.

COOLLLDDDD weather propane

Because we were headed to very cold temps and would be stationary for some time, I installed a two-port external propane adapter onto our propane tank.  This allows me to either feed propane to an external grill/appliance (one with a regulator) or to feed propane in from an external tank(with appropriate adapter hoses).  When we were in northern Wisconsin for a couple of weeks this winter (early 2020), this came in very handy as we would have used up our main propane tank long before it was time to leave.  I had two portable tanks, thus could swap them out for refill.

Water Expansionwater expansion chamber

I noticed a water connection under my bathroom sink weep occasionally.  I finally traced the issue to 130+ PSIin the water system after taking a couple of showers.  Apparently, cold water filling the heater, then expanding as it heats up with no place to go creates tremendous pressure. I installed an accumulator that provides a place for the expanding water to go as well as allows the water pump to cycle less often. These are inexpensive, can be installed almost anywhere in the water system, and relatively easy to install. Note, I was under a time and parts availability constraint when I installed this – so this installation looks truly ugly.  While I was at it, I also installed a separate pressure gauge that lets me see the pressure inside the system, independent of the city hookup pressure regulator.  UPDATE: we purchased a fancy, electronically controlled, variable speed pump – that should have been quieter.  Its not quieter.  It normally runs around 60 psi, but some days, for no reason, it runs up to 80 or so.  We can tell because its even noisier than usual.  Someone at support at the company tried to tell me not only did the resevoir mess it up but the guage would cause it to not operate correctly.  Go figure.  Gauge and expansion chamber continue to work.

Damaged CB coax
Damaged CB coax
Nearly folded CB coax
Nearly folded CB coax

Communication Radios

We often disconnect a short way before an RV park or boondocking spot, and we sometimes caravan so having a working CB is something we wanted.  We even bought the “preinstall” from Tiffin when the RV was ordered.  It never worked right.  I had discovered the cable was mangled with pliers while installing and the CB end connector was bad. shortening the cable, and reinstalling a good connector only helped a little. Thus, installing the CB became part of the cabinet install.  We ended up replacing the entire CB cable and the antenna to get it all to work.  We also installed a newer, better CB.  Unfortunately, we weren’t happy with the CB when caravanning.

Update:  In the end, we installed console GMRS radios and short (6 inch) upgraded antennas, using the 50-ohm coax that had been run for the CB radios.  While they are not perfect, they are far quieter (extraneous noise wise) and work over a far greater range than the CBs ever did.  When parking in a site or the rare occasion when we need to travel with our Toads unhooked, our spotters use handheld GMRS radios.  We also installed a “trucker” GPS antenna to improve XM radio reception.

Sub-basement lights

We installed a set of AC powered strip lights under the RV.  They were plain white and so bright it lookedsubbasement lights “like someone left the basement lights on”.  Eventually we replaced these with some RGB led rope lights that allow us to choose colors or color-changing patterns.  Not near as bright.  The picture to the right is the original lights.

The doghouse

A never-ending story.  When Rover was Pulling up a steep hill – the engine noise is a bit more than we’d like.  More than some other gas Class A’s we’ve ridden in.  So we decided that if we had the chance, we’d add some additional sound deadening under the front cab area.  We also found plans for a wooden cabinet to replace the plastic junk Tiffin attaches to the top of the Doghouse with plastic console removeddoghouse cover.  Not wanting to pull the cover more than once, we planned to pull the cover, add insulation then build and install the new cabinet.

Staples galore
Staples galore

So, with all supplies ready, I started removing the carpet – as the 6 inches of carpet around the doghouse was one and the same as the carpet on the doghouse.  If I had had trouble on the road and a mobile mechanic needed to get in there, it would have taken a hour just to get the cover off.  First, pull off the dash access port – find the 4 screws that lock the bottom of the dash plastic to the plastic cabinet.  Then take apart and remove the plastic cabinet from the doghouse.  THEN… either tear up the carpet around the edge (50+ staples) or take a sharp utility knife and cut the floor attached carpet from the doghouse carpet.  Finally, there are 6 screws – crooked doghouse/tile gapsthree in front and three toward the back that hold the doghouse in place.  They are buried in the carpet and can be hard to find.  I chose to pull the carpet off the floor as it had become quite dirty and generally unsightly.  Under the carpet were large gaps as Tiffin didn’t run the tile all the way to the doghouse.  We installed cove base over the floor new consolefor now.  When I get back home to my spare floor tiles, I’ll fill in closer to the doghouse frame and install some smaller trim.  We built the cabinet with a drawer and installed metal cupholders with LED lights in them.  Then we added some rubber cup inserts.  Much nicer looking, way more useful.  And the engine seems quieter as well.

Update:  The cove base has worked surprisingly well – I have no plans to replace it at this time.  

Bathroom Carpet

Debbie doesn’t like cold floors for those midnight trips to the bathroom, so we installed carpet in there.  I started with pieces of cardboard I laid down, trimming to size and taping together.  I ended up with one “piece” the shape fo the floor.  I laid that over a piece of carpet and cut just outside the lines – making sure the door entrance ended up where there was the edge tape sewed on the carpet.  I started there, working around, trimming the carpet with a sharp blade.  Just to make sure, we added some of that waxy tape to the floor to help hold carpet in place but probably didn’t need it.  Every 8 or 12 months, we buy a new carpet square and use the old one as a template.  It takes me less than an hour, start to finish.

Gally Vallance

Galley VallanceThe Tiffin “valance” around the gally window was quite a small hole, plus it took up at least 4 inches of the countertop.  We removed the valance (which weighed something like 60 pounds as it was real stone tile) and tossed it.  I reversed the window shade to put the shade closer to the glass.  Then I built a lightweight wood valance that sloped toward the window at the bottom, saving lots of counter space.  Currently, it’s painted white, but a future project will apply some sort of other finish to it.

Terrible Valances

RV manufacturers as a class, all go overboard with the wood trim and glitz.  We desperately needed some color in the main New Valence Coversroom.  The valences that extend way down also tend to get in the way.  We pulled them down, Alternate Colors Mood Lightingremoved the lower extensions, and re-covered the valences with a nice sky/cloud print material.  I purchased a set of color-changing LED strip lights (Menards?).  We bought some ¾ wide quarter-round PVC trim that turned out to be an exact match for the living space cabinets.  We command-strip-velcro’d that to the bottom of the cabinets and added the LED strip to the back of that.  Now the valence print looks completely different depending on what color the strip is set to.

Knobs, who needs these knobs?

We really didn’t like the doorknobs and drawer handles that came with the rig.  The ends stuck out and would catch on clothes.  Eventually, we found a setNew Knobs and Handles Deb liked and two Home Depots later, we had enough to replace every bit of hardware in the RV.  I’m still trying to sell off the old set on eBay.  The original knobs were T shaped and constantly caught on things and would constantly come loose. I did install the new ones with lock washers.

Kitchen Fan

The MaxFan that came in the RV kitchen area could be opened and turned on from the Spyder control panel in the kitchen. But other functions such as fan speed, thermostat, etc could only be controlled by getting on a stool and pushing buttons on the fan itself.  We replaced the fan with a remote-controlled unit.  We only hooked up the “Fan” wire from the Spyder system, that we leave on, and control all functions with the remote control.  I wish I knew if there was a way to reprogram Spyder functions.

Cooler AC

We read that white Air Conditioner covers run much cooler than the black ones installed by the factory.  I don’t have specific numbers for the difference, but in order to get the most from our units, we ordered white covers.  While we were swapping them out, we checked and sealed any air leaks in the “cold side” and added an extra layer of insulation on the main cold box using Reflectix and aluminum tape.  We also insulated the cold refrigerant line that runs from the evaporator to the compressor.  They do seem to be more effective on a sunny day.  Later, we added soft start modules to both ACs, hopefully allowing them to run on lower current circuits.

Medicine cabinet shelves

The medicine cabinet is quite tall and has but one shelf (plus the bottom).  We sometimes travel with three people.  I pulled the cabinet off the wall, moved the one shelf (parts from the kitchen cabinet), and added another.  Now we have three shelves and can utilize the space much better.

There is a small storage cabinet above the toilet.  It had no dividing shelves.  I added a shelf in the middle to make the storage of towels and wash clothes more efficiently.

Mirror, Mirror on the wall….

The bathroom had a mirror on the medicine cabinet door and one on the right wall. Moved Mirror I presume the thinking was to provide two angles for the wife.  But both mirrors were close to the corner and just plain inconvenient.  We tore the mirror from the right wall and placed it between the medicine cabinet and the window.  The mirror was GLUED and STAPLED to the wall – so a nice picture was placed to cover the mess left by removing the mirror.

Really, no towel rack?

There was no towel rack in the kitchen.  Nor was there any place on the cabinets toMagnet installed in towel rack base easily hang a couple of towels.  We are currently trying the refrigerator door.  Yes, the door and no we didn’t drill holes. I attached the mounting plates with VHB tape, then attached the rack to the plates.  So far it is holding.  Update:  I found some magnets at the hardware store designed to hang hooks from metal racks.  I tapped the hole in the steel magnet cover, then epoxied a bolt into the base.  Once hard, I added a nut and threaded the magnet on till it was just flush with the base.  Works great.

Shower power

Soap dishWe added a soap tray via waterproof command strips, and across the shower, up high, we added several command strip washcloth hooks.  We replaced the original showerhead with a better one and a valve that shuts off completely.  We also replaced the stiff hose with a flexible one and removed the hose from the ring that limited its movement.  Part 2: putting the soap holder right below the shampoo shelf turned out to be an open invitation to knock the soap or entire tray on the floor.

UPDATE: We moved it over between the door and the rail the shower sprayer was mounted on – haven’t knocked either down since.

Added Paper towel rackPaper Towels are a must in the kitchen

Even big expensive RVs don’t seem to come with paper towel racks.  We used the same one we had in our last RV – it has just enough resistance to allow one to easily tear-off sheets and we installed it under the kitchen cabinets behind the sink.

Better Cooking Light

The microwave came with a built-in light over the kitchen work space.  It came with a punyLED panel light under microwave incandecent bulb.  Being almost useless, we found an LED bulb that was brighter, but even that wasn’t good enough.  We found a  flat LED light that we velcro’d under the microwave which provides really nice light.

Who’s there?

We installed a Ring doorbell outside and a Ring Camera inside.  Both connect to our protected WiFi which connects to our hotspot.  I installed a 24V transformer so the ring stays charged.  This lets us keep an eye on the doggies when we are away and keep an eye on our site as well.  The Ring is set to detect motion and save vids to the ring server and notify us when we have the Away setting turned on.

WeBoost and hotspot
Everyone needs Internet

Since we planned to boondock a lot and since most campground WiFI networks are poor and/orWeBoost Cellular Repeater antenna overloaded, we wanted better Cell/Internet connectivity.  We purchased an AT&T hotspot  as a part of our family cell plan and a WeBoost cell booster.  For the outside antenna, I purchased some PVC pipe connectors, screw clamps, and an extensible painter’s pole.  I have two sets of PVC connector mounts – one down low for travel and one up high for maximum vertical reach.  Update:  When we first installed this, I used what cable I could get quickly – 75-ohm coax designed to cable nets.  The booster really wants a 50-ohm low loss cable, which I have purchased and installed.  I also got a directional antenna to try to provide a bit more boost in some situations.  When there are nearby cell towers, the directional antenna seems to make little difference as the tower decides what power everyone should talk so the additional gain seems to get quickly offset.  I presume it would make more difference if we were miles from a single tower.

UPDATE:  Since we were going to be out and about again this summer, hopefully boondocking, we chose to add a second cell vendor.  To facilitate this process, we bought a PEPWAVE Max Transit Duo router capable of using two cell vendors at the same time.  We added an exterior (roof mount) antenna to provide better access.

PEP MIMO/WIFI/GPS antenna
PEP MIMO/WIFI/GPS antenna

Our second vendor choice was a bit limited, we picked up a T-Mobile BYOD sim from Nomad Internet.  Throughout the six months we had it we managed to get about 2 months or working service.  After the fourth sim stopped working correctly, I insisted on a refund (we had to pay 12 mo in advance).  I received a partial refund which I reluctantly accepted and moved on.  I then ordered an FMCA router, also T-Mobile which seems to be working fine.  It’s not quite as fast as the ATT tower at our current location but it lets me use both providers through my PEPWAVE.

Couch Mods

The provided sleeper/couch is, in theory, quality construction.  But the vinyl upholstery was too slippery for our little dogs.  We purchased a coarse cloth and made covers for the cushions.  BUT the seats were also rock hard.  Ten minutes into sitting in them and they were terribly uncomfortable.  Pressed for time (leaving for warmer climes), we purchased some foam locally and refilled the cushions.  Now they are just a little soft. Update:  We still had the original foam, which I split down the middle and added the soft foam on top of the half-thickness hard foam.  Now the cushions seat much better.  On one of our trips, we were going to be having a guest – sleeping on the fold-out sleeper built into the couch.  It uses an air mattress to save space and weight.  But the thought of blowing up an air mattress and letting it out every day seemed like a hassle.  It is a fairly thin air mattress and getting the air pressure “just right” is key to a good night’s sleep.  We opted to give away the mattress and buy a good quality foam mattress that would still fold up – and that worked well.

Power, more Power, Solar Power

We decided early, that between the residential fridge, all the accessories that used AC power, plus computers, that the factory Solar and Inverterprovided batteries weren’t going to be sufficient.  They required long charging cycles with the generator.  While we were out at Quartzite – Battle Born had a tent sale – and we picked up four 100 Amp-hour lithiums.  They make a big difference.  Once we got back home, we added 800 watts of solar, with a system designed for 1600 watts.  800 still doesn’t quite keep up with our needs, but it reduces generator time, so long as we aren’t shaded.  At the same time, we weren’t happy with the 2000 watt inverter.  We had to be careful what appliances we ran at the same time – we overloaded it a couple of times and had to perform a manual reset.  Since we had also installed a Victron Battery monitor, and a Victron solar controller – we added a Victron Color Control Console and a 3000 watt Victron inverter.  So all our battery systems could be watched under a single monitor and via the Color Control Console or an app on our phones, even remotely.  More on the solar etc install can be found here:  Solar Installs

DC components w/labels
DC components w/labels

UPDATE:  I have designed a “replacement” for the Tiffin/Lippert DC distribution panel.  It is all based on discrete components and thus takes up a lot more room.  It is amazing just how much stuff, tiff stuffed into that tiny panel – and not amazing why parts of the original panel failed so often.  I have come accross other tiffin 32SA owners that have had the inverter switch fail and one whose panel caught fire (he was outside and managed to put it out before the fire spread).  I have one addition to this configuration that is coming.  When we started out with the lithiums – I never saw the batteries charging from the engine more than 90 amps.  I believe this is because the lithiums were never mostly discharged.  We often used the generator when boondocking rather than the engine to charge.  One night we spent parked behind a restuarant.  We hit the road in the morning, still dark out after running the batteries down to about 40%.  I looked at the charging rate and it was 120 amps.  Plus headlights and anything else – thus pushing the generator on the engine to its limit.  I’m about to install a DC to DC converter.  This will limit the engine to house batteries to about 40 amps, which is fine because we rarely need to charge up the house batteries quickly with the RV engine.  It should keep me from pushing the engine alternator so hard.

Hindsight

The Tiffin provided rearview camera looks straight down the back of the RV.  This might be great for backing up, but provides no Original Rear Cameraview down the road behind.  There are side-view mirrors of course, and turn cameras as well.  But 50 plus feet back, it becomes hard to gauge distance in the mirrors and harder in the turn video, especially at New Rear View Cameranight.  We purchased a set – monitor and 4 cameras.  I ran three cables to the rear of the RV and mounted one camera at the top rear to look back into traffic.  It is fed to the new monitor and provides a full-time rear view.  We are discussing having two side cameras that watch the rear tires (like many of the diesels have) and possibly putting the fourth camera on the rear air conditioner – looking forward to watching for branches and such in campsites.  Update: During one of the CB/GMRS/XM radio work sessions, I added a video cable going up to the front air conditioner.  Now we have a forward-looking view with the camera mounted right at our maximum height.  We did use this a couple of times to check clearance at a gas station and a decorative sign in a small town.

Dash electronics need a base

Rover’s dash had a plastic access panel in the top middle of the dash.  It was flimsy and had a textureNew Dash Top Panel that would make it difficult to attach devices.  I removed the cover and used it as a template for a nice piece of 3/8ths plywood.  Stained and with four screw holes and it provides a good platform to mount the dashcam, TPMS, GPS, and monitors.  In addition to the camera and GPS, we have a rearview camera and our combined Brake/TPMS/Level monitor.

We have dashcams in all our vehicles.  Rover wasn’t to be an exception.  I created a camera mount on the side of the TV box and ran power.  Later we decided to move it to the center of the dash.  I couldn’t find Ignition power up by the TV box – so we had to manually turn it on and off.  I think the dash mount provides a better view and access to Ignition power.

Shelf instead of slide
Shelf instead of slide

Paltry Pantry

Next to the microwave, was a small pantry with a pull out drawer with two side accessible shelves.  It was all made with 3/4 lumber, making it space inefficient and heavy.  Worse, it had three slides to support it – nice they tried to support it well, but since the slides were just as misaligned as the rest of the drawer slides in the RV, it was very stiff to pull out.  I tried several times to realign them.  Finally, frustrated, we realized just how inefficient space utilization was.  Only 40% of the cabinet space was available on the slide-out drawer.  I pulled the slide-out and disassembled it.  I installed a single shelf, then used the slide front as a cabinet door.  We still don’t use all the space, but it’s nice to know it all is actually usable if we wanted to.

Screen doors need love too

We found it tremendously useful to have an additional handle on the inside of the screen door on all our RVs.inside screen door handle  It was one of the first things we added.

Screen door inside/outside handle: Open Screen when outside door open.when the main door is latched open and only the screen door is closed – the latch is OUTSIDE the door.  One has to slide a panel open to open the door from the inside.  We found a little lever that allows one to open the screen latch from the inside without sliding the panel.  It’s not entirely natural, but it is easier to use.  This one cost $5.  Why would Tiffin cheap out on such a small but terribly useful addition.

End Tables

Our main couch was mounted several inches from the rear slide wall. It was wasted space and there was no place to put a cup, poor Alexa or anything else.  The empty space wasn’t enirely square so I measured carefully, cut a nice piece of oak – added three under rear end tablelegs, stain and filled in the space.  I cut the shelf board so it would be a snug fit all by itself.  The three legs were just thin trim strips of oak, held in place by 90 degree brackets.  Mostly, they just support any weight on the shelf. We still store the sink covers a stool, etc below.

.
Front end, hinge, underFront end, hinge
front end table above

We also made a fold-down table for the forward end of the couch. There are two aluminum flats that slip in between the couch and the back of the dinet seat.  The flats are screwed to a piece of oak, to which is screwed a hinge and the top on the other side of the hinge.  If we want to use the fold out bed, the shelf can be pulled up a bit, then folded up out of the way.  Its hardly perfect, but it does work.  UPDATE: this arrangement would never stay level.  I pulled out the hinge and installed a right angle bracket.  The shelf is sturdy, stays level and doesn’t really need to flip up as we don’t use the fold out bed.  If we did, the shelf could be flipped around and hang over the dinette seat.

12V port next to bed

Organizers and accessories

TV remote holders – Debbie found a couple of leather “holsters” that we command-strip-velcroed to the wall.

12V port by bed – We planned to boondock a lot and I wanted to use my CPAP with a 12V adapter instead of 115V AC. Its more efficient to convert 12 to 24 than convert 12DC to 115 AC and back to 24DC.  Twelve volts was already present in that cabinet for the  USB port so it was just a matter to drilling a hole and paralleling the new port.

Dumping and Filling

Yet another “old man comfort” item was a foldable stool I keep in the water bay. Being under a slide, and having to access controls that are quite low – being able to sit down is amazingly useful.  Besides, with the kinds of things that happen out there, you really don’t want to be kneeling in the dirt next to dump hoses.  Speaking of which, I also keep a spray disinfectant to hit my shoe bottoms with just before I return to the RV.

Knees need love too

Nearly half the storage doors are under slides.  All of them can end up on gravel, wet grass, sand – you name it.  I saw these carpet squares (waterproof backs) at the Quartzite tent and bought a hand full; cut them in half and put one in each storage bay.  Thus I can kneel on them, keeping my knees clean and the rocks off my arthritic knees.

phone holders, both sides
phone holders, both sides

Phone Holders

One of the first things we did to Rover was to add a couple of phone holders on each side for the driver and passenger. While neither of us is using our phones all the time on the road, it is a convenient place to keep them.  I added a 12V socket for phone charging on the driver side.   Adding charging ports on passenger side is on our todo list.

Black shades are Bland!

We have swapped out the black shades on several of our windows for printed shades (using aBathroom valence and shade upgrade. secret proprietary process).  The long galley shade, the slide out end shades and the bathroom window shade are all printed with pictures we have taken.  The shade by the dinette contains a US map for reference.  We still plan on replacing the shade behind the couch.

DISH Traveller

Our RV came with a Wally Dish Receiver but no antenna.  We purchased a Dish Traveller antenna and bracket and mounted it on the roof.  With the bracket however, we could quickly disconnect it and use a cable to connect to the RV via a port in the water bay and place the dish antenna somewhere on the ground where it can get a view to the southwest or southeast.  So far, we’ve not had to move the dish receiver.  We did replace the Wally at one point as the original one was getting quite flakey.

Weather Station

Former cell repeater post used for weather station.Weather StationWe purchased a weather station (temp, wind, rain) and installed it on the pole we used to use for the cellular repeater.  It shows us wind speed and direction as well as temperature, humidity and precipitation.  Its connected back to a server so we can monitor conditions when away from the RV.  I have to take it on faith that the rain gauge works – we’ve been here for two months and have no had enough rain to trip the rain gauge.

Hitch Doubler

We originally carried our bikes on the back of the pickup truck.  That not only made our overall rig
Hitch doubler for Bike rack
longer, but we didn’t always want them on the back of the truck.  So I picked up this hitch doubler – a 10k pound capable version.  I also picked up the “u-bolts” to help keep the play out of the system.  The bike rack itself has some play in it that I need to figure out how to remove so the bikes don’t rock back and forth.  We much prefer the bikes not being on the back of the truck all the time.

Spice and Oil Rack

Spice rack in kitchen
Spice rack in kitchen

This is the spice rack I built for the kitchen.  Its on the right wall of the countertop (next to refrigerator).  There is a similar rack in the bedroom for essential oils.

Kayak Rack on Bluebird


Kayak Rack on Blue

We carry our two person kayak on the top of our pickup truck – with custom built slides.  We unstrap from the racks and slide backwards over the bed and down to the ground.

Solar Installs

Tomorrow’s Journey Solar Saga

We had hoped to install solar while we were on our winter trip to the southwest.  Sometimes things just don’t work out the way we dream. But the trip was fruitful in many ways – we met a great solar supplier and ended up with four Battle Born batteries at a great price from the Battle Born booth at Quartzite.  But, I’m getting ahead of myself.

Debbie on our daughter’s
roof, preparing to feed wires down through the front cap.

Our basic philosophy on solar was to start with a modest build but design and install wherever possible with a maximum installation in mind.  The solar also needed to make sense with our power needs and the size of our battery bank.  Based on our expected needs and the fact we already had 400 amp-hours of lithium, we choose to install four 200Watt solar panels, but to design and install components based on an eight-panel, or 1600 watt system.  Our wire sizes, combiner box, and solar controller are all sized to carry that size of a system.

wasted could be battery space
Wasted could be battery space

Installing more battery will require restructuring and/or expanding the battery bay.  Our current bay barely holds four batteries, but mostly because it uses a slide-out tray (which requires slack cables and a place for them to move) as well as a control panel that just plain wastes space.  It doesn’t make sense to double the solar but maintain the same battery, so any future expanse will be quite a project in itself.

We also chose to upgrade our inverter from a Magnum 2000 to a Victron Multi 3000.  This brings all of our major power devices under the same vendor and common management software as well as providing a bit more power and functionality. On our first winter trip, we had to be a bit more conscious of our AC current draw than we’d like to be. Also the Victron will work in Hybrid mode – monitoring the current and picking up the slack when needed.

Parts

We met Matt Dalley from ContinuousResourses.com under the big tent at Quartzite.  He was quite helpful.  While I am an electrical engineer, I had no experience in the world of RV solar and have more than a few things to learn.  Matt was very helpful, working through several renditions of my design and answering more than a few questions.  In the end, I ordered almost the entire system through him.  I am quite happy with all the products I received. One thing I must note though. When you order, you won’t get one big box with all your parts.  You will get a box every day or so, for a week or so, drop-shipped from various locations around the country.  In the end, this saves you money and I wasn’t in a big hurry anyway.

So, here is a list of parts:

  • 4 x 200W Hitec solar panels
  •  4 x panel mounting bracket kits (can be upgraded to tilt)
  •  30 ft of 4/0 ultraflex battery cable and lugs (new wire from inverter to batteries)
  • 30 ft of 4AWG UltraFlex battery cable and lugs (roof combiner to solar controller to inverter)
  • 80 ft each of red and black, 10AWG PV wire for wiring panels (enough for 8 panels no matter where they are on the roof)
  • 4 x MC4 2 in 1 branch connector (that I actually didn’t need, was thinking parallel at one point)
  • Combiner box with 4 inputs and breakers for 8 panels (4 sets of 2 in series)
  • Blue Sea Class T fuse block with cover (up to 400Amps) and 400 Amp fuse (for the eventual replacement of Battery catastrophic fuse)
  • Victron Energy ve.direct and RJ45 UTP network cables and adapters
  • Midnite Solar Baby Box and two breakers for switching panel inpu and Controller output.
  • Blue Sea Battery Switch
  • Victron Energy SmartSolar 150/100 Tr Charge controller with Bluetooth
  • Victron Energy MK3-USB interface
  • Victron Energy MultiPlus 12/3000/120-50 Inverter-charger 120V
  • Victron Energy WiFi module (to connect Color Control to wifi)
  • Victron Energy Color Control GX monitor
  • Install kit – lots of misc parts.

Some explanation.  The 4/0 cable from the inverter to batteries was because the 2000 watt inverter in place was on the left side of the RV and batteries on the right.  While 2/0 cable that was in place is technically big enough for 3000 watts, it seemed like a good time to make sure the longer cable run was as good as it could be.  

Combiner just forward of rear cap.
Combiner just forward of rear cap.

I studied for some time as to where to put my combiner box, and thus the drop through the RV to the left rear bay where the controller would be installed.  After carefully considering the various walls and closets I might end up drilling through, I decided no drilling through the cabin was the solution. I chose to put the box at the rear of the RV and bring the wire down through the rear cap.  This made the future runs to solar panels mounted forward fairly long, but I ran through the calculations and the losses were minimal.  Better to make the series panel runs longer and the combiner to solar controller shorter as it carried the higher combined current that was easily handled by the 4AWG cable. 

Series or Parallel?

I waffled for some as to whether it would be better to put all my panels in parallel or some combination of series+parallel. With all the air conditioners, vents, etc. on the roof, something is going to be shaded any time the sun isn’t nearly overhead. If you shade one panel of two in series, you lose most of both. The other side of the argument though is if you put panels in series – there is more voltage for the controller to work with early and late in the day. I even considered running a pair of wires to each panel and doing the serial/parallel connections in my combiner box. In the end, I chose to serial two panels, each on the same side and parallel the groups. At least two panels should be making full power no matter where the sun is coming from. If I decide to change things later, it’s just a bit of wire, some connectors and/or 4 more panels.

Burnt Fuse and busbar
Burnt Fuse and busbar
Melted Inverter Switch
Melted Inverter Switch

A bit of relevant history. While we were out west on our first trip, we were clearly having a voltage problem – the inverter would complain about low voltage or simply drop out if we ran more than one appliance. This was a big part of the reason we went ahead with the Battle Born battery purchase at Quartzite.  The culprit, however, turned out to be a faulty catastrophic fuse connection mounted on the back of a switch control panel in the inverter power path.  The poor connection generated so much heat, it melted part of the panel including the inverter power switch which caused it to fail.  The fuse itself never failed – just the interconnect was resistive and thus got very hot. As a part of my solar plans, I intended to replace this entire panel, but because of time constraints, this part of the plan wasn’t executed.  It is still on my ToDo list. See the rest of this story on Youtube, Here.

Finally, we considered long and hard, on how to attach the panels to the roof.  So, this is a good time to segway into the FIRST install:

My Daughter and husband also bought 2 x 100-watt panels and an MPPT controller in Quartzite.  We were uncertain how they would use the panels – whether like a suitcase or on the roof.  It’s a rubber roof – so VHB tape was out.  The roof construction is basically rubber over 3/8ths (if that) plywood over styrofoam. Dropping screws into that combination doesn’t instill one with great confidence that the panels won’t become airborne. After some consideration, we decided to use butyl tape, well nuts and of course self-leveling sealant.  Since my arthritis had kicked into overtime, my duties were primarily supervising and/or critically important adjustments.  Thus, I made the mounting brackets out of angle aluminum (using jigsaw and drill press in the garage). I also drilled and tweaked the holes in the roof for the well nuts, but not a lot else.  We drilled the holes and carefully trimmed them so the well nuts would just fit.  We used ½” diameter, 1” long with ¼-20 brass inserts along with 1 ¼” stainless bolts. We attached the brackets to the solar panels, set them in place and marked the holes.  Then we moved the panels off, drilled the holes, pushed in the well nuts, laid a small amount of butyl tape around the hole.  Then the panels went back in place, were screwed down tight (two bolts per bracket), then self-leveling sealant on top.  They are very solid.  We configured the panels in series and taped down the solar wire with 2-inch segments of Eternabond tape.  A small roof entry box was mounted over the hole drilled in the front cap top to feed the main wires down to the solar controller and combination circuit braker and cutoff switch that we mounted inside the front storage.

2 x 100 Watt panels
Holes for Well Nuts.

Overall, it was a simple install.  Because the panels were going near the front of the trailer, we chose to use 6 brackets each.    We ran 4AWG cables from there to the batteries. Two hundred watts has been a good fit with the two 6V GC2 lead-acid batteries they have for storage.  It has been a couple of weeks now, and the panels keep up with most of their daily needs as long as they are parked in the sun.  They don’t have a big inverter, so they do run their generator when making a pot of coffee or when they need to run the Air Conditioner.

So back to the main event. I survived the mini-build, so we decided to go ahead and tackle the class A build.   This is central Illinois in the springtime, so we had to try to plan for a few days without major rain.  Of course, the forecast changes hourly, so we got chased indoors more than once.  

Our panels went on first. They came with four brackets each that hooked on and provided a pivot point that could be used with additional hardware (not supplied) to allow the panels to be tilted.  These brackets hooked over the panel and attached with a single bolt. I’m a “two is one and one is none” kind of guy, so we drilled and added a second bolt to each bracket. I scoped out 9 possible locations on the roof – we choose 8, then the four initial spots that would be toward the rear – but reserving the area at the very back for getting on/off the ladder and for the combiner box.  The box was bolted to the main cabin roof, but a 90 degree piece of PVC electrical conduit exited the back and entered the back cap for running wires down to the controller.  

We installed the panels pretty much the same way as with the earlier install – except we used the provided VHB tape between the roof and brackets and stainless bolts into ½” by 1” well nuts with ¼-20 stainless bolts, two per bracket.  They aren’t going anywhere.  We ran the solar wire – setting up the two left panels in series and the two right in series, each pair to a breaker, connected in parallel before the 4AWG cables going down to the solar controller.  

Our left rear storage had the Magnum inverter, our power controller/EMS and our 50 Amp shore power cord already in it.  But there was plenty of room for the solar controller and the slightly larger Victron Inverter/Charger.  We mounted a piece of plywood on the inner wall, then the solar controller and the mini breaker box.  The cable from the panels went into the mini-breaker box, through a 60-amp breaker – out to the controller, then the output from the controller went into the mini-breaker box, through a 100-amp breaker and out to the main DC power cables that fed the Victron Multi.  The mini breaker box not only protects the input/output of the controller, but also allows me to isolate the controller from the panels and the batteries.

Then I double checked that all the power lines to/from the Magnum had corresponding connections on the Victron Multi (and were labled), took a deep breath, and swapped them out. And it all worked!  Once I remembered to flip on that tiny switch in front of the Victron Multi to the correct position..  

DC power distribution
Back of DC power distribution Panel

To back up a notch, we ran the 4/0 cables from the Victron (left rear storage) to the battery bay (right rear), pulling out the 2/0 that was there.  When I got up to pulling the old control panel – I realized I needed more hardware I didn’t have on hand, so we hooked up the 4/0 cables without changing the panel.  Here is one of those odd things you run into that makes you scratch your head (or bang it on the wall), wondering WHY they build RV’s this way. The ground cable from the inverter, ran to a bolt mounted on the battery bay wall.  From there a ground cable ran back to the top of the frame to another bolt (totally inaccessible).  From there a ground cable ran to the batteries.  Thus, I was not able to replace all of the 2/0 cable – at that time.  Most of it, however, is better than none of it. When I deal with the panel, I will make sure I have 4/0 though the entire path from battery to inverter.

Since the main inverter switch is actually in the right-side battery bay, an unintended consequence of this particular install was that the Solar only charges the batteries when the inverter switch is on.  Not too big a deal as when we are using the RV, it is always on.  When in storage, it might be a different situation, so likely I will move the Inverter switch to the left storage bay, or reinstall the 2/0 positive cable just for the solar controller to the battery (my preferred solution).  This last solution would also bypass the main battery switch, so I could shut off power to the RV, but still keep the batteries charged.

So, we’ve only had a few days of actual use – boondocking.  On a mostly sunny day, it keeps up with our use (refrigerator, coffee maker, TV, microwave, two laptops running much of the day, etc).  Since leaving home (a week now), we’ve only run the generator once for about an hour. In South Dakota it is running 600+ watts several hours of the day and we hit over 800 once.  I’m quite happy with it.  I’d be happier of course, with more battery and more solar so we had a several day reserve, but that won’t happen for a while.

Futures?

Replacing the battery switch/breaker panel and catastrophic fuses.

Rerouting some of the AC power. Right now, the AC leg that goes through the inverter only connects to the various plugs and appliances in the coach. The air conditioners and fireplace, for example, come off the EMS/Gen/Shore switch BEFORE the inverter. In theory, I could run one air conditioner off my inverter and batteries by using the inverter to boost power from a low current shore power source, But only by rerouting AC power for the air conditioner THROUGH the inverter. This will probably wait until we upgrade the system to more battery and more panels and I would install a switch so the air conditioner could be powered via either path. .

The only special tool I purchased for this install was a hydraulic crimper. I purchased this one: https://amzn.to/2FbUiXc on Amazon for $45.99.

Appropriately size well nuts can be hard to find. I scrounged through every hardware store in town, to find enough. While local HW stores would carry them, they often only had half a dozen or so of each size in stock. Make sure you get the ones with the thin shoulders so your brackets sit on the roof. The well nuts, or expansion nuts, as some places call them, need to be longer than the plywood/fiberglass on the roof – thus I used 1 inch long. I had some 1/2 inch versions and they didn’t hold properly in tests.

Feel free to ask any questions, here or over on youtube. Get to know use here on Youtube and please subscribe.

Postscript. I continue to be happy with the system. It won’t keep up with our needs when we are shaded as we are this week in Glacier, but it is working as designed. Its cool that as long as I have cell, I can connect back and see how the entire system is doing.