DIY Van Electrical System: Solar Power and Starter Battery

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Today, we're diving back into our camper van build to tackle one of the most daunting tasks: finishing the electrical system. If you’re planning your own DIY van conversion, this blog post will walk you through the process of installing an electrical system in a way that’s accessible to beginners like us.

Caveat: We’re not professional electricians—just two soon-to-be-van lifers learning as we go. This is our way, not the way, so please consult a professional if you’re unsure!

The Basics of Our Van’s Electrical System

An electrical system is the heart of a camper van. It powers everything from your lights to your appliances. Here’s a quick rundown of what we installed:

1. Lithium Batteries

   • We used two Lion Energy lithium batteries (about $900 each, though ours came with the van!). These batteries are lightweight, efficient, and perfect for van life.

2. Three Charging Methods

   • Solar Panels: Two 200W Renogy panels mounted on our roof.

   • DC to DC Charger: Allows the van’s engine to charge the lithium batteries while driving.

   • Shore Power (Optional): We opted out but left space for future installation.

3. Inverter

   • Converts DC power from the batteries into AC power for 110V outlets.

4. Bus Bars, Fuses, and a Shunt

   • These components distribute and manage power safely across the system.

What We Used to Build Our Van Electrical System

Everyone’s electrical build is going to look different, and that simply is based upon the needs and monetary ability the someone may have. These are some of the items we used to build our system (it’s a hefty list so save this post!):

• Lion Energy Lithium Batteries

• 200 Watt Renogy Solar Panels

• Renogy 40A 12V/24V Auto DC Input MPPT Solar Charge Controller

• Solar Connector Waterproof In-Line Fuse Holder w/ Fuse

• Solar Panel to Charge Controller Adaptor Kit

• Solar Y Branch Connectors MMF+FFM Pair

• 2000W inverter

• 12 Way 12V Blade Fuse Block,12 Circuit ATC/ATO Fuse Box Holder

• Kohree Battery Disconnect Switch 12V, 12V-48V Battery Isolator Power Cut Off Master Switch

• Renogy 500A Battery Monitor

• Renogy 12V 60A DC to DC On-Board Battery Charger

• 12v Bus Bar 5 Post 300A Power Distribution Block 5/16" Battery Terminal Block Stud with Cover and Wire Lugs

• Klein-kurvel crimping & stripper tool

• 14 Gauge Marine Wire

• 2 Gauge Battery Cable Copper Wire

• 12 Gauge Duplex Marine Wire Tinned Copper Boat Cable

• RED WOLF 50A Amp Circuit Breaker

• RED WOLF 40 AMP Car Circuit Breaker

• Renogy Set w Holder + 100A ANL Fuse

• TopstrongGear Solid Brass 0/2/4 Gauge 250Amp ANL Fuse Holder with 250Amp Fuses

• DC Miniature Circuit Breaker

• 12V USB Outlet Wired USB Charger Multi Port

• 30W USB C Recessed Power Strip,Flat Plug Power Strip

Step 1: Connecting the Wiring

We started by connecting wires between components like the batteries, bus bars, and DC to DC charger. Here’s what we learned:

• Use the Right Gauge Wire: The wire size depends on the amperage and distance. For our system, we needed multiple types of wiring from1-gauge for high-current connections and long distances to 14-guage for some of our lower power items like our 12v puck lights.

• Crimping the Lugs:

  • Strip the wire just enough to fit the lug securely.

  • Use a heavy-duty crimper for a snug fit.

  • Heat-shrink tubing seals the connection for added safety.

• Safety First: Double-check each connection and ensure no wires are exposed to prevent electrical shorts or fires.

Step 2: Installing the DC to DC Charger

The DC to DC charger connects the van’s main battery to the lithium batteries, allowing them to charge while driving. This component ensures that the charging process is safe and efficient, especially for sensitive lithium batteries.

Step 3: Solar Panel Setup

Our Renogy solar panels are mounted on the van’s roof and feed into a charge controller. The controller regulates the electricity flowing from the panels to the batteries, protecting them from overcharging.

Step 4: Testing the System

After everything was connected, we tested the system to ensure it worked seamlessly:

• Check all connections and tighten any loose terminals.

• Use a multimeter to measure voltages across components.

• Turn on devices to confirm proper functionality.

Lessons Learned

1. Plan Ahead: Having a detailed wiring diagram saved us time and stress.

2. Buy in Bulk: We purchased lugs and wires in bulk since combo kits to save some extra cash.

3. Take Your Time: Rushing leads to mistakes—double-check every step!

Final Thoughts

Installing a van electrical system is intimidating at first, but with patience and research, it’s entirely doable—even for beginners. Completing this project was a huge milestone in our van build, and we’re excited to share more of our journey with you.

Have questions or want to share your experience? Drop a comment below!

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Join Us on Our Van Build Journey!

Thank you so much for following along on our van build journey! Building this community is truly rewarding, and we’d love to hear from you. Please subscribe to my YouTube channel, and feel free to leave any questions or suggestions in the comments. Whether you want more van build tutorials, insights into our van life prep, or a Q&A, we’re excited to create content that helps you on your journey too. Until next time!

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