The EarthRoamer XV Xpedition Vehicle has been
years in development by Earthroamer Founder Bill Swails and
President/CEO Michele Connolly. During the last two months
Off-Road.com has had a privileged look inside the incredible
machine known as the Earthroamer Xpedition Vehicle. And ORC readers
had a chance to go one-on-one with EarthRoamer Founder Bill Swails
himself during an interview with ORC staffers. And now going one
step further, we present to you a tremendously detailed article
direct from Bill Swails and EarthRoamer President, Michele Connolly
as they address the most common questions directly to you via
Off-Road.com
Many thanks to Michele and
Bill for taking the time to detail many of the important aspects of
the EarthRoamer Xpedition Vehicles for our off-road readers! Visit
EarthRoamer at www.EarthRoamer.com
EarthRoamer XVs: Systems
Make the Rig
by Michele Connolly and Bill Swails, EarthRoamer
founders
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We frequently get asked, what makes your vehicle
different from RVs of similar size. This question is often
difficult to answer, not because we can’t clearly define how
it is different, but rather because the list of items is SO LONG!
We’ll do our best to briefly describe the systems on
EarthRoamer Xpedition Vehicles (XVs) and why they are better suited
to get you off the beaten path.
There are probably as many ideas about what defines
the ultimate expedition camper as there are people who dream of
owning one, so we’ll start with our requirements for an
expedition camper.
In its simplest form, we wanted an expedition camper
that would allow us to:
1. Travel safely and reliably to remote places, even on very rough
roads and trails
2. Travel comfortably at highway speeds with up to four adults
seated in a spacious cab
3. Enjoy a secure and weatherproof shelter with all of the comforts
of home
4. Be totally self-contained and independent of external water or
power hookups.
While the concept is simple, designing and building
an expedition vehicle that meets these objectives is very
challenging.
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Using a diesel 4x4 extended cab American made truck
as the foundation of our original Dodge Ram based expedition camper
proved to be an excellent choice. An American made truck is easily
serviced throughout the western hemisphere, and offers on road and
highway speed comfort and capability. The extended cab provides for
carrying additional passengers or provides easily accessible space
for equipment such as camera gear. We found that four-wheel drive,
single rear wheels and a relatively narrow width are the most
important attributes for traveling on remote roads. Back roads in
the US, Canada and Mexico are frequently very narrow making dual
rear wheeled vehicles impractical due to their increased width.
Dual rear wheels are also a problem on rough trails since the dual
rear wheels do not follow the track of the front wheels, and rocks
have a tendency to wedge between the dual tires resulting in tire
damage.
Other choices were more difficult. Should we go with an automatic
or manual transmission? What wheelbase would be short enough to
give good off-road capability but still provide the load carrying
capacity to carry enough food, fuel, water and gear? Which brand of
truck and (equally important) which engine should we go with.
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Designing the XV-LT/Ford F-450
platform
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After carefuly evaluating the truck platforms offered
by Dodge, Ford and GM, Ford quickly rose to the top of our list.
Out of the three major diesel light truck manufacturers, Ford is
the only one to offer a cab-chassis truck with a four seat extended
cab. The cab-chassis has straight frame rails, which greatly
simplifies camper design and allows for a larger interior standup
height. The F-450 also has a gross vehicle weight rating (GVWR) of
15,000 pounds and a gross combined vehicle weight rating (GCVWR) of
26,000, which would give us to an estimated 2,500 pound payload and
a towing capability of up to 12,500 pounds. If the 15,000 pound
GVWR wasn’t enough, we could step up to an F-550 with a
17,500 pound GVWR.
The balance between having a camper that is large enough to carry
gear and be comfortable, yet small enough to travel to be
maneuverable is delicate. In our experience, a vehicle with an
overall length of around 23 feet is very capable and maneuverable,
but still large enough to provide spacious living quarters –
even on extended trips. With a 60 in cab to axel, 162-inch
wheelbase F-450 cab chassis, we could build an expedition camper
that would meet our length criteria. The low straight frame rails
of the chassis cab, enabled a camper design with a six foot six
inch standup height.
Ford Super Duty’s come with straight axels and manually
locking hubs, which we prefer when four-wheeling. Finally, the new
6.0-liter Ford engine has the highest torque and horsepower in its
class, providing an incredible 560 foot-pounds of torque and 325
horsepower. After driving the new 6.0-liter with the 5-speed
Torqshift transmission, we were sold; this thing hauls!
After debuting our new XV-LT at Ford’s Centennial celebration
in Detroit in June, we spent the next three months crisscrossing
the country showing our F-450 based expedition camper. During this
period, we accumulated over 15,000 miles on our truck, and even
managed a couple of off-road trips. Our initial infatuation with
the new 6.0-liter engine and five-speed Torqshift transmission has
grown into a serious love affair. The 560 foot-pounds of torque,
expanded gear ratios of the five-speed tranny, tow haul mode and
massive brake calipers make for a truck with amazing acceleration,
low end grunt, highway cruising speed and amazing stopping power.
This truck drives and handles more like a sports car than a serious
truck with a 15,000 GVWR. Off-road, the King off road shocks soak
up the boulders, and the Goodyear MTR’s provide awesome
traction.
Many RVs are pieced together using a metal or wood frame structure
with many seams, and aluminum, plastic or fiberglass skin. Foam or
fiberglass insulation is often used in-between the framing to
provide insulation. This can result in a structure with water leaks
and poor insulation.
For the EarthRoamer™ XV-LT body, we used a molded monocoque
design that is completely weatherproof and very lightweight. The
carbon fiber reinforced body is structurally robust and is
constructed of a fiberglass sandwich with a structural foam core,
using the same techniques used to construct many high-end yachts
and aircraft. This composite laminate shell is lightweight,
extremely strong, and provides excellent thermal and acoustic
insulation properties. Unlike wood structures it can never rot.
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The combined bathroom and
shower has a small wash basin and is trimmed in
teak.
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To ensure structural integrity in demanding rough road conditions,
we incorporated a tried and proven triangular mounting system to
isolate the camper from torsional loads caused by frame flex. The
front camper mounts were mounted to the truck frame using urethane
mounts to isolate vibrations. The single rear mount is on a pivot
to allow the frame to flex without transferring torsional loads to
the camper. Isolating the camper from torsional and vibration
forces allows it to withstand extended periods of travel in
demanding rough road conditions without damaging the interior
components and cabinetry.
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Typical RVs rely on propane, generators, and external hook-ups to
provide the necessary power to function. Generators are frequently
loud and only provide power when running. Many campgrounds prohibit
the use of generators after certain hours. Any appliances that rely
on generator current to run will not be operational unless the
generator is running. Frequently the most scenic and desirable
campsites can be found in national forests, national parks, state
parks, and remote areas with no hook-ups.
We designed the EarthRoamer XV-LT for stand-alone power operation.
All heating and cooking is done with high efficiency diesel
appliances. The thermostatically controlled forced air diesel
furnace will easily maintain a comfortable interior temperature
even in the coldest weather. Our prototype vehicles have been in 10
degree below zero weather in Colorado and the diesel furnace easily
maintained an interior temperature over 70 degrees. In the winter
there is no need to drain water tanks to prevent freezing, just set
the thermostat to maintain a cozy camper temperature. The diesel
furnace only burns .06 gallons of diesel fuel per hour at the
highest output level.
For a cook stove we chose a ceramic cook-top diesel stove. It burns
less than .05 gallons of diesel per hour at the highest heat level,
burns cleanly, exhausts to the outside and only draws .15 amps of
12-volt power. With no open flame it is safe, and the smooth cook
top is easy to clean.
While propane appliances are ubiquitous in RVs, we decided not to
use propane for several reasons. First and foremost is safety.
Propane is a volatile and potentially dangerous fuel. Since propane
is heavier than air, if a propane leak develops in an RV the
propane can accumulate at the bottom of the camper until an
ignition source ignites it. An open propane cooking flame in the
relatively tight space of a camper is also a risk. It can be easy
to accidentally ignite a paper towel or paper plate with an open
propane flame in the relatively tight space of a camper.
Additionally, a gallon of propane only has about 65% of the energy
content of a gallon of diesel fuel, so much more propane must be
carried to get the same energy content as diesel fuel; a waste of
both space and energy.
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Reliance on propane can cause many annoyances. When propane is
burned, one of the byproducts is water vapor, which contributes to
excessive humidity and condensation inside the camper. When
traveling on most ferries (including Alaska Marine Highway and
British Columbia ferries) propane tanks must be sealed closed. RVs
that depend on propane for refrigeration will have no refrigeration
while on these ferries. Propane can be difficult to find in remote
areas, and it’s difficult to top off a partially full tank.
We decided to “just say no” to propane and to use only
diesel and el
ectric appliances for heating,
cooking and refrigeration in the XV-LT.
Camper battery power is provided by two 255 amp-hour absorbed glass
mat batteries for a total of 510 amp hours of capacity. The
advantages of AGM batteries are that they require no maintenance,
withstand shock and vibration better than any standard battery, are
sealed against hydrogen leakage and spilling even if they are
broken, and can survive most freezes. AGM batteries are
“recombinant” – which means the oxygen and
hydrogen recombine inside the battery. The recombining is typically
more than 99% efficient, so almost no water is lost. Since the
internal resistance is extremely low, there is almost no heating of
the battery even under heavy charge and discharge currents. AGM
batteries have a very low self-discharge rate, so they can sit in
storage for long periods without discharging.
These batteries are charged by two 185-watt solar panels located on
top of the camper, and when the engine is running dual 130 amp
alternators provide plenty of charging power. When camping or
parked, power is provided by the camper batteries and the roof
mounted solar panels. These single crystal 185 watt modules feature
17.5% encapsulated cell efficiency and 14.2% module efficiency
– the highest efficiency commercially available. Using
breakthrough technology perfected in the space cell program, these
modules allow for maximum usable power per square foot of solar
array. Safe, clean, reliable sources of energy, these photovoltaic
modules are designed for large electrical power requirements. Based
on the technology of crystal silicon solar cells developed over 35
years, this module has superb durability to withstand rigorous
operating conditions. A solar charge controller controls solar
power and 12 volt power is distributed through a marine circuit
breaker panel. The solar panels and batteries easily have enough
power to run the refrigerator, air conditioner, convection
microwave, lights, water pump, fan, coffee maker, and laptop
computer. On the rare occasions that more power is required than
the solar panels can replenish during extended stays in camp, a
simple idle of the engine will recharge the camper battery.
Sufficient power is simply not a problem.
By using solar panels, large alternators, large batteries and
efficient appliances, the need for a generator has been completely
eliminated. This results in a camper that is much more convenient
to use and frees up valuable space normally taken by the generator.
The camping experience is much more enjoyable without the noise of
a loud generator.
Like most RVs, one of the earlier EarthRoamer prototypes used a
3-way absorption refrigerator (propane, 12 volt dc and 110 ac),
which was a constant source of frustration. When running on 12
volt, the absorption refrigerator drew too much power for the
camper battery making 12-volt power only practical while driving.
The propane flame would go out while driving, which meant that
propane could only be used while stationary. This resulted in a
constant need to switch between 12-volt and propane, or the
refrigerator would no longer run and food would spoil. Another
problem with our absorption refrigerator is that it had to be level
or it would not cool properly. Refrigeration was a constant problem
with the 3-way refrigerator in the EarthRoamer prototype, and on
more than one occasion the end result was a dead camper battery or
spoiled food.
For the EarthRoamer™ XV-LT we chose a high efficiency 7.0
cubic foot 12-volt compressor refrigerator/freezer that only draws
5.0 amps when it is running. This refrigerator solves all propane
related refrigeration problems and even has a separate freezer
compartment. The solar panels and battery easily keep up with the
refrigerator, so you can let your stocked refrigerator run all the
time and be ready to head out on an adventure on a moments
notice.
The EarthRoamer™ XV-LT uses a cassette toilet waste handling
system popular with European camper designs. By using a cassette
toilet, exposure to waste is minimized and waste disposal is
simplified. The waste holding cassette is accessible via an access
door from the outside of the camper, and it is simply removed and
emptied at a dump station, conventional toilet, or pit toilet. The
black water tank within the cassette has a capacity of 5 gallons.
The more frequent need to dispose of waste associated with this
smaller tank is easily offset by the convenience of emptying it.
There is no large waste tank to empty and no sewage hose to handle,
and no complex black water system to maintain and repair.
Adequate fresh water capacity is essential for extended remote
camping, and so we decided on a minimum 50-gallon standard
freshwater supply (with the option to upgrade to 100 gallons). A
dual filtration system and guidelines for chlorinating the water
are supplied to help ensure water quality. In addition, all water
tanks including the fresh, gray and black water tanks are located
inside heated compartments in the camper enabling camping in below
freezing weather with all water systems operational. To prepare for
a trip, simply fill the water tanks via the gravity water fills
located on the passenger side of the vehicle.
By eliminating the space normally required for propane tanks and a
generator, the EarthRoamer™ XV-LT we were able to provide
over 75 cubic feet of storage space – a storage volume we
believe to be unmatched by any similar sized RV. This space along
with an estimated payload capacity of 2,000 pounds will allow us to
carry supplies, gear, tools, spare parts and sporting equipment for
extended trips.
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With the permanent over cab loft, and lower
convertible bunk, sleeping space is provided for four
adults.
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The total interior cabinet storage space is 53 cubic feet providing
plenty of space for storing clothing, food, pots, pans, photography
equipment, laptop computers and supplies required for an extended
expedition. The entire interior camper back wall is comprised of
two cabinets: one with drawers and one with flexible, space ideal
for hanging clothes and storing equipment cases. The first cabinet
provides over 11 cubic feet of drawer space and the clothes closet
provides over 27 cubic feet of storage. A slide out pantry provides
over 9 cubic feet of easily accessible storage for food and
supplies, and the refrigerator freezer will hold 6.3 cubic feet
cold beverages and food.
The total exterior storage space is about 24 cubic feet in three
separate lockable storage compartments. The back of the camper
houses a 12 cubic foot outside accessible storage space for large
long items like skis or fishing rods and bulky items such as tents,
folding chairs, barbeque grills, tool boxes and inflatable kayaks.
This space is approximately 86 inches wide by 20 inches tall by 12
inches deep. The door hinges at the bottom and opens to form a work
surface. Within the compartment are external shower controls ideal
for beach showers, washing off gear or cleaning fish. Above the
long storage space are two additional compartments, each with an
addition storage space of approximately 6 cubic feet.
The solar panels, roof hatch and vent fans can be located along the
driver side of the roof to allow for roof top carrying of long,
relatively lightweight items like a canoe or kayaks. The spare tire
is a hard mount point for heavy or bulky items like fuel cans,
mountain bikes or kayaks. The Class V receiver hitch can also be
used for bike carriers or a motorcycle carrier. The 560 foot pound
torque rating of the diesel engine and the class V receiver hitch
will enable pulling of a boat, ATV, horse or camping trailer
weighing up to 12,000 pounds.
We designed the interior space of the EarthRoamer™ XV-LT to
be “flexible” to accommodate performing various tasks.
The interior space can be quickly reconfigured depending on the
task requirements. For example, the seatbacks of each bench seat
doubles as a flip up counter. When preparing a meal or whenever
additional workspace is required, simply drop down the seat cushion
and flip up the counter. In the galley area, when the granite seat
back is flipped up, the entire counter is over 6 feet long.
The dinette table located between the bench seats has “flip
up” leaves that allows us to reduce the size of the table for
occasions when only two people are eating, and to provide easy in
and out access to the bench seats. When the table is fully
extended, the table spans the space between the bench seats to
provide comfortable dining for four. In the extended position, the
table can be rotated 90 degrees and lowered to covert into a second
bed 40” x 80” in size. A permanent king sized bed is
located over the cab so a bed is always available without taking up
or converting other camper space. Sleeping space for up to four
adults is available. Ample headroom above the over cab bed allows
this space to double as a lounge area for watching television.
The entry door to the wet-bath and the closet door are designed be
opened and latched together to form a changing room with easy
access to dry towels and clean clothes located in the closet.
With the EarthRoamer™ XV-LT, efficient space utilization and
thoughtful design provide a highly functional and spacious
interior, even though the exterior camper dimensions are relatively
small by RV standards. The interior of the camper has the look and
feel of an upscale yacht. Light colored wood expands the space and
leather-like vinyl seat cushions combined with high-end appliances
and counters deliver the comforts of home in a functional, durable
and easy to clean space. A very generous interior standing height
of 6 foot 6 inches contributes to the spaciousness.
The best one-word description of the EarthRoamer™ XV-LT is
freedom. The XV-LT gives you the freedom to travel confidently and
comfortably anywhere you want, whenever you want, without concern
for the weather or season. Whether it’s a long weekend at the
lake or an extended trip to South America, the XV-LT is the
civilized way to escape civilization.
It’s the freedom to head out on a trail in the middle of Baja
to a pristine secluded beach. It’s the freedom to camp safely
with all the comforts of home high in the mountains – in the
middle of winter! It’s the freedom to hit the road for a
four-month expedition to Alaska and wake up to a different
beautiful scene outside your window every morning. Fishing, cross
country skiing, snowmobiling, hunting, mountain biking, hiking,
photography, surfing, boating, racing – no matter what your
passion, the EarthRoamer™ XV-LT is the perfect base camp. The
XV-LT expedition vehicle provides the freedom to escape the
stresses of everyday life and lets you enjoy nature in peaceful
isolation. With an EarthRoamer™ XV-LT you truly can
“Live Your Dream!”
Our XV-LT is built on an F-450 Super Cab converted to
single rear wheels – but for customers who need more cab
space, more towing capacity or dual rear wheels – we offer
any combination of F-450, F-550, SuperCab, Crew Cab, single rear
wheels or dual rear wheels. Our only requirement is that the base
Ford truck be a 60 cab to axle chassis cab, with a Power Stroke
diesel engine. Whether you’re off on an expedition to hit
trails in South America, or looking for a quality rig to tow your
heavy boat or horse trailer on the highway, we can build an XV-LT
to meet your needs.
The EarthRoamer XV-LT wouldn’t be possible
without the technical assistance and incredible products of some of
the world’s best companies.
ATS Diesel Performance www.atsdiesel.com/
These guys are the diesel power experts and provide EarthRoamer
with ongoing technical support.
Diab www.diabgroup.com/
Supplies core structural foam and solutions for our composite
sandwich XV-LT body that is light, strong, and provides good
insulation
Ford www.fordvehicles.com/
Builds the incredible Ford F series Super Duty Chassis Cabs that
are the foundation of the XV-LT.
Goodyear www.goodyeartires.com/
Manufacturers the best tire we’ve found for both on and
off-highway driving.
Hella www.hellausa.com
Hella HIDs light the way for EarthRoamer.
Norcold www.norcold.com/norcold_home.cfm
Builds the best high efficiency 12 volt compressor refrigerator
that we have found
Sharp www.sharpusa.com
Provides the most efficient solar panels and air conditioner we can
find for the XV-LT. Also provides the incredible Aquos LCD TV; the
brightest, clearest flat panel TV we have ever seen and our
convection microwave oven.
Thetford www.thetford.com/thetford_home.cfm
Provides the perfect solution for our XV-LT waste management
system
T-Rex Engineering www.trexengineering.com/
These guys are the experts when it comes to suspension tuning. Want
to make your big, heavy Super Duty handle everything from expansion
joints to the back roads of Baja? T-Rex can design a suspension
system using King Off-Road shocks that will tackle any terrain.
Ute Ltd. www.uteltd.com/
Distributes the coolest looking, lightest and strongest heavy duty
aluminum bullbar (bumper) on the market