Now for something completely different: 2023 Chevy 3500 Extended Express, Yea I know.....It isn't cool.

[chuppie]

Rebuilt Battery Box.

Prototype Version 3. I promised myself I would not spend anymore time on this but I seem to keep modifying it. I will build a new box since this on has gone thru numerous modifications. What became apparent is that I didn't have enough power connectors when I added a diesel heater, and 2 Grandkids who seem need more DC charging power than a small town with their electronic devices. More on Diesel heater later.

Features:
200 AH Lithium Battery

40 Amp DC to DC charger

10 separate Fused Anderson circuits.

Insulated Battery

Low temp solar and alternator charging disconnect.

Battery state meter

800 Watt inverter

300 Watts solar

MPPT charge controller with Bluetooth

USB charging port

 

[chuppie]

HCALORY Diesel Heater

This post is share what I have done and learned.

Advice:
3" HVAC flex ducting is too restrictive. In my case I need about 10' from ground to RTT. 4" works fine. You will need to adapt from 3" to 4"

Picture shows:
3" Bad
4" Good
Save yourself some money, get 4".
It will go into an overtemp condition with 3" duct at 8 '

Make a power supply for bench testing. It costs about 10 bucks. You need 10 amps due to glow plug when first starting.


Make a 10 gauge power cord, mine is 25' so I can use it away from Van. Voltage drop on small gauge wires will cause low voltage shutdown.

 

[chuppie]

More

Anderson connector added.

 

[chuppie]

Tidbit
The OEM fuel hose fits 1/8" brass barb fittings. I'm going to adapt a portable boat fuel can to supply it.
I need some advice on boat fuel tank fittings. I bought fittings to fit Yamaha but the brass tank fittings is different that the hose side fitting. Are there standards? I could not find it online.

Thanks

 

[chuppie]

So a few more things. I installed the air inlet inside the case. Works fine, plenty of ventilation. I modified the exhaust bracket for easy on and off since it sticks out too far for transport.

 

[chuppie]

Some random pictures I in case you are the only person who hasn't seen one.

 

[chuppie]

Comments,
If was advertised as 8kw but the rating Tag says 5kw

It draws almost 10 amps at startup and about 1 amp on low.


Apparently exhaust should be sloping downward away from unit but this setup has it pointing to the sky. I ran it for 8 hours straight, nothing leaked out of it.

This thing is not waterproof/resistant!
I need to make a Doghouse for it since it rains 90 percent of the time I camp.

 

[chuppie]

Rating tag showing 5kw.

 

[chuppie]

It occured to me I didn't comment about the heat, it puts out a dry odorless heat much like a furnace.

The HCalory seems decent. The Pelican style case is OK but nothing like a real one. The fuel tank makes it have to be stored upright or it leaks from the lid. I will report back when I get the boat 3 gallon tank set up working.

 

[chuppie]

300 watt portable full sine wave inverter with 12 hour timer. I have digital controlled electric blanket that we want to possibly use in the RTT.
The digital blanket controller doesn't function correctly on the main modified sine wave inverter.

 

[chuppie]

More tidbits on Diesel Heater

3"to 4" adapter. I recommend metal due it being close to exhaust.
I had a 4" 90 silicone that was left over from another project. It works perfect for the 4" flex duct. Doesn't seem to be affected by the exhaust heat.

 

[chuppie]

Lastly since I trust this heater as much as I trust a Harbor Freight jack stand, I made two hanging combo C0 / Smoke detectors. One for RTT and the other for Grandkids/daughter/SIL tent. I just used some binder clips and some short pieces of chain to make hangers. Simple and gives me a warm fuzzy.

 

[chuppie]

Back to the Van. If you notice in early pictures, I have 4 crossbars under the RTT. I did this because of the suggestion in one of the Bush RTT videos. Well first, it only comes with 6 tie downs and second the spacing
Interferes with the optimal ladder bracket placement for side entry. I am going to remove the a middle bar and readjust the spacing. I am only mentioning this to save somebody some money and a lot of unnecessary work.

 

[Trixxx]

Great build thread! Really enjoyed seeing the thought process and steps!

 

[chuppie]

So I paid I think about $35 for a 300 watt pure sine wave inverter shown above which very very inexpensive. I was suspicious that it might really be a modified sine wave inverter claiming to be a pure sine wave inverter.
Well it really is a pure sine wave inverter with proof. Picture on bottom is the PSW inverter.
Pic on top is my 800 watt modified sine wave inverter which should really be called a modified square wave inverter but whatever.

I know. Quit being geek.