Custom build - 2020 Westfalia Club Joker 4Motion - Offroad build thread

[larrylamb]

Nifty Velcro storage nets. Perfect for the felt roof of the club joker. Also from Tactic Vans. Got 6 of them.

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Hi, did you install the 12v socket here? Any info? Cheers.

 

[Webbah_in_Switzerland]

Hi, did you install the 12v socket here? Any info? Cheers.

Yes I sure did. Very useful for charging phones and tablets, etc. and having access to them from the bed. There is also a 12v socket in the top cabinet inside too for my 5G Router.


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[larrylamb]

Yes I sure did. Very useful for charging phones and tablets, etc. and having access to them from the bed. There is also a 12v socket in the top cabinet inside too for my 5G Router.


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Which circuit did you tap into,? i know there is some mini trunking running through the wardrobe up to the control panel.

 

[Webbah_in_Switzerland]

Which circuit did you tap into,? i know there is some mini trunking running through the wardrobe up to the control panel.

I have a very custom setup with a 2000 watt Victron inverter under the fridge in the cabinet where the step is stored. This has a large cable run from the battery and then from that I tapped several other circuits with fuses for various purposes. Both 220v sockets are rewired to the inverter as well. If on EHU this goes via the inverter to switchover.

Finally I rewired the Westfalia charger to the inverter with a remote relay switch so if the starter battery needs a boost or charge I can flip the switch and it will emulate EHU (visible as plugged in on the Westfalia control panel) and charge the starter battery from the inverter and lithium batts. Now 2 batts of 180Ah each for a total of 360Ah under the seats.


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[larrylamb]

I have a very custom setup with a 2000 watt Victron inverter under the fridge in the cabinet where the step is stored. This has a large cable run from the battery and then from that I tapped several other circuits with fuses for various purposes. Both 220v sockets are rewired to the inverter as well. If on EHU this goes via the inverter to switchover.

Finally I rewired the Westfalia charger to the inverter with a remote relay switch so if the starter battery needs a boost or charge I can flip the switch and it will emulate EHU (visible as plugged in on the Westfalia control panel) and charge the starter battery from the inverter and lithium batts. Now 2 batts of 180Ah each for a total of 360Ah under the seats.


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Very custom indeed
I'll have a poke around at some stage see what circuits are nearby.

 

[Chris Ratay]

Hope you're still enjoying it.

I'm assuming with the snorkel you added the hoses to raise the breathers, or...?

Where's your spare?

You mentioned surfing - how does it handle in sand? I've heard it's easy to get into trouble in soft sand.

 

[Webbah_in_Switzerland]

Hope you're still enjoying it.

I'm assuming with the snorkel you added the hoses to raise the breathers, or...?

Where's your spare?

You mentioned surfing - how does it handle in sand? I've heard it's easy to get into trouble in soft sand.

Hi Chris,

Indeed I’m loving it. Thanks! The spare is mounted underneath in the normal location. I had to do a slight modification to the plastic tray to fit a BFG but it works fine. Just need to air it down to 1 bar and spray some silicone and it slides right in.

I also did add the air breathers for the diffs and these are then mounted up high near the starter battery. Also I have a rubber cap to cover the diesel heater exhaust if I am going through deeper water to prevent ingress into the heater.

I haven’t had any challenges in sand but I wouldn’t want to cross the Sahara desert most likely. There isn’t really any difference between mine and a Cali other than it’s a LWB so 30cm longer and 2.85 meters high. I do have Goldschmidt air suspension though which updates the load rating to 3.5 ton. It’s important to lock the air suspension prior to any off roading to avoid the compressor and leveling to constantly adjust. And for sand to air down and feather the throttle.


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[babble]

Hi Chris,

Indeed I’m loving it. Thanks! The spare is mounted underneath in the normal location. I had to do a slight modification to the plastic tray to fit a BFG but it works fine. Just need to air it down to 1 bar and spray some silicone and it slides right in.

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Hi Webbah, I'm just trying to fit my wildpeak 235/65 17R under the van, and wondering what i need to do to get it to fit. Some people seem to just get longer nuts for the back and deflate the tyre, but i'm not sure that will work. I could cut or even remove the plastic part at the back i guess. I see there are alternative holders for sale, but they seem to require cutting the plastic anyway. Is this what you had removed?

 

[Webbah_in_Switzerland]

Hi Webbah, I'm just trying to fit my wildpeak 235/65 17R under the van, and wondering what i need to do to get it to fit. Some people seem to just get longer nuts for the back and deflate the tyre, but i'm not sure that will work. I could cut or even remove the plastic part at the back i guess. I see there are alternative holders for sale, but they seem to require cutting the plastic anyway. Is this what you had removed?
View attachment 126025

Hi Babble,

This plastic was cut a bit, but my mechanic did it for me while on the lift. I can’t crawl u see and take a photo right now as we’re parked on wet and dirty grass. We then only inflated to 1-1.5 bar and sprayed silicone spray on the edge of the Tyre and it slid in fine.


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[babble]

Hi Babble,

This plastic was cut a bit, but my mechanic did it for me while on the lift. I can’t crawl u see and take a photo right now as we’re parked on wet and dirty grass. We then only inflated to 1-1.5 bar and sprayed silicone spray on the edge of the Tyre and it slid in fine.


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Thanks!! Is that for a 235/65? I guess i'll deflate mine, get a bit of washing up liquid on it and give it a go!

 

[Webbah_in_Switzerland]

Thanks!! Is that for a 235/65? I guess i'll deflate mine, get a bit of washing up liquid on it and give it a go!

Yeah I had the same Falken size in there. I recently mounted my BFG’s as I’ll be going mild to hardcore off-roading the second half of July and the Falkens were pretty worn down and don’t want to risk it. He cut the plastic without removing it but I can’t recall if that was done for the recovery hooks we mounted or the Tyre. I’d use Silicone spray as it will last while dish soap will wash away. Just so it’s also easy to remove if needed.


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[Californication69]

How are you enjoying the Lithium batterys in the Joker Dude ?
I have had a little read up on them, and they would appear to be the dogs dangly bits in how they will be used in an off grid setup.
Super fast charge time, and usable storage of 100% ?
So the old batts were 2x 75 AGM, so only a usable state of 75ah?

 

[Webbah_in_Switzerland]

How are you enjoying the Lithium batterys in the Joker Dude ?
I have had a little read up on them, and they would appear to be the dogs dangly bits in how they will be used in an off grid setup.
Super fast charge time, and usable storage of 100% ?
So the old batts were 2x 75 AGM, so only a usable state of 75ah?

LiPo batts are fantastic! I have mine setup to max drawdown to 10% charge so 90% usable. I’ve always had LiPo batts in my Joker but previously had 2*100Ah and now have 2*180Ah for 360Ah. Working from Van is like home now without a care in the world.


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[wildslammer22]

LiPo batts are fantastic! I have mine setup to max drawdown to 10% charge so 90% usable. I’ve always had LiPo batts in my Joker but previously had 2*100Ah and now have 2*180Ah for 360Ah. Working from Van is like home now without a care in the world.


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I think you might have said before but where did you mount your DC/DC charger? I’m eyeing up either a Roamer or Fogstar 230a under seat battery but space will be VERY tight with the fuse box under one seat and the diesel heater under the other!


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[Webbah_in_Switzerland]

I think you might have said before but where did you mount your DC/DC charger? I’m eyeing up either a Roamer or Fogstar 230a under seat battery but space will be VERY tight with the firebox under one seat and the diesel heater under the other!


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I mounted a Victron BuckBoost 100A under the drivers seat (LHD) but it required some slight modification of the base to make it fit. Not near the van now to take a photo though! I’m quite sure neither of those batts will fit under the T6.1 seats. They are made for Ducato’s. That’s why the max I could find were the 180’s.


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[Webbah_in_Switzerland]

I think you might have said before but where did you mount your DC/DC charger? I’m eyeing up either a Roamer or Fogstar 230a under seat battery but space will be VERY tight with the fuse box under one seat and the diesel heater under the other!


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Actually I had a photo already

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[wildslammer22]

I mounted a Victron BuckBoost 100A under the drivers seat (LHD) but it required some slight modification of the base to make it fit. Not near the van now to take a photo though! I’m quite sure neither of those batts will fit under the T6.1 seats. They are made for Ducato’s. That’s why the max I could find were the 180’s.


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I’m told they would fit and the dims seem to confirm that but I assume that’s with nothing else under the seat. I would probably go with a 30a Orion DC-DC which is more compact and probably two batteries. Even then I might have to raise the passenger (LH) seat a little.


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[Webbah_in_Switzerland]

I’m told they would fit and the dims seem to confirm that but I assume that’s with nothing else under the seat. I would probably go with a 30a Orion DC-DC which is more compact and probably two batteries. Even then I might have to raise the passenger (LH) seat a little.


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There’s a new Orion 50A you might want to look at. It’s all a matter of math and time. With 100A to charge a 280Ah battery you’d need 2.8 hours of driving. With 50A you’d need 5.6 hours. With 30A well over 7 hours.


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[Webbah_in_Switzerland]

I’m told they would fit and the dims seem to confirm that but I assume that’s with nothing else under the seat. I would probably go with a 30a Orion DC-DC which is more compact and probably two batteries. Even then I might have to raise the passenger (LH) seat a little.


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I’m told they would fit and the dims seem to confirm that but I assume that’s with nothing else under the seat. I would probably go with a 30a Orion DC-DC which is more compact and probably two batteries. Even then I might have to raise the passenger (LH) seat a little.


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Here’s what it looks like under my seats. This was with the 100A batts. Forgot to take a photo with the new 180’s.

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[The Merle]

Very custom indeed
I'll have a poke around at some stage see what circuits are nearby.

I had a 12v socket done there by dealer they ran it off leisure battery (fused), there’s a space to run cables under metal trim side step then under kickboard (water tanks), in boiler area then up wardrobe. Guess they didn’t want to mess with westfalia original electrics

 

[The Merle]

I think you might have said before but where did you mount your DC/DC charger? I’m eyeing up either a Roamer or Fogstar 230a under seat battery but space will be VERY tight with the fuse box under one seat and the diesel heater under the other!


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Unless you are power hungry or don’t move for weeks or with no solar then one 230a will be plenty.
I have 280a no solar yet and haven’t dropped below 92% on bat! 30a is plenty to top up. (Fridge on full time and not using diesel heater)
You can get most things to run off 12v these days.

 

[Ch1pbutty]

I had a 12v socket done there by dealer they ran it off leisure battery (fused), there’s a space to run cables under metal trim side step then under kickboard (water tanks), in boiler area then up wardrobe. Guess they didn’t want to mess with westfalia original electrics

Thinking about maybe fitting a lithium battery when our leisure needs replacing as it’s still the original one. We only have one leisure battery, but assume that the factory charger would not be suitable and would need changing, does the split charge still work or would this need some adaption.

Also when we are on EHU, the current charger charges leisure & engine.

It’s T5.1 2015 without start / stop.

Wondering if it’s worthwhile, or , are we better keeping things as they are?

 

[Webbah_in_Switzerland]

Unless you are power hungry or don’t move for weeks or with no solar then one 230a will be plenty.
I have 280a no solar yet and haven’t dropped below 92% on bat! 30a is plenty to top up. (Fridge on full time and not using diesel heater)
You can get most things to run off 12v these days.

And that’s the thing. People need to calculate their consumption and go from there. Add 5G and/or Starlink, charging e-bikes, laptops and tablets, or other worldly pleasures like air fryers or Nespresso machines and things add up. What works for you doesn’t work for others that have different requirements or desires. Many can certainly do just fine with OEM AGM batteries. Others they enjoy having an extended home experience in a small package need to do the calculations and work from there.


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[wildslammer22]

Here’s what it looks like under my seats. This was with the 100A batts. Forgot to take a photo with the new 180’s.

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Thanks & yep, there’s no way the under seat model will fit under there!


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[The Merle]

Game changer lithium is in my view whether you use lots or little. Wish I had done it in my joker years ago.