Setting up the Landcruiser

Since purchase of the VX Landcruiser (LC) in mid 2012 we have clocked up 26,000 km, some towing our previous van and the rest on long distance country roads or around town. We are averaging just over 15 litres per hundred kilometers, with the non-towing average around 12 and the towing average up around 20 to 24.

It is amazing how much headwinds affect fuel consumption, particularly when towing. Alli always seems to cop the tail winds although she says it is my heavy right foot. If I use cruise control over undulating country there can be extensive variation in fuel usage. It will be good to have an extra 40 litres of diesel in the box on the Bushtracker. 

In preparation for picking up the van we have made modifications that, we are advised, will ensure the LC is set up to tow what will be a heavier van than any previous. This post follows and explains those modifications, just for the record.

Shortly after purchase we had an additional fuel filter installed to ensure we always had clean fuel.  These engines seem to dislike dirt or water in the fuel and there are stories around that crook fuel can lead to the complete replacement of an engine. We needed to take precautions more so around fuel than around spare parts. I'm not sure what I'd do with the spare parts anyway.

In addition, an ARB Bull Bar with a Warn winch was fitted, both precautionary. A Safari snorkel was installed to ensure we had clean and dry intake air, in both dust and through water crossings.

The fitting of the snorkel appeared to create an annoying wind noise over 80 kph. Assisted by ARB Maroochydore, we discovered that a small plastic cover underneath the rear view mirror was vibrating as the air deflected off the snorkel. A small strip of black gaffer tape soon fixed the annoying problem.

We also had an ARB compressor installed under the bonnet to service two rear airbags which we added to assist towing (see the inlet nipples on the plug photo below). 

 
In addition, a Redarc electronic brake controller for towing was installed. I've modified the Redarc switch by gluing a plastic nib to it so that I can tell where it is set without looking. I have used the Redarc several times now and find it fine although some people say it is too sensitive.

We also had the wiring for towing installed, using a seven pin plug for the van, an Anderson plug for constant charge from the car to the fridge while driving....

 

... and a rear view camera plug that connected to a screen on the car rear view mirror. This is mainly for towing the van, a necessity as cars often slip in behind the van, out of sight of the extended mirrors. However it is also handy for hooking up to the van, balancing the view from the in-car rear view camera. The set up of cameras under the tail gate has to be off centre because the tail gate lock is centred, so they give a slightly distorted view which is annoying when you need to be quite centred.

We also had two high powered Lightforce driving lights fitted as well as a GME UHF radio with a high gain aerial.
 

All of this added over $8,000 above the price of the car.


Another couple of thousand dollars saw the suspension upgraded with OME nitrocharger shock absorbers and increased spring capacity both front (100kg) and back (200kg).  This raised the car a little and evened out the dip being caused by the heavy front bull bar. It also improved both ride and handling while giving us about 3,500 kg GVM rating (up from 3,200 kg standard). However, the installer forgot to do a proper wheel alignment and a set of front tyres was scrubbed on the edge within 5,000 km. Fortunately, the installer admitted liability and we are negotiating replacement tyres. I'm actually looking for a contribution towards four 18 inch Bridgestone 697 Desert Duelers which I'd like installed before we pick up the van. These are the same tyres as will be on the Bushtracker and I believe their price will come down in the new year.

A further modification was the installation of a Steinbauer engine management module (see above next to the extra fuel filter), costing about $2,700. This is not simply a chip. It is and engine management module with a set of 10 chips that monitor performance and activate changes in the engine operation so that there is maximum torque while towing. The module provides on average about 25% better torque although in lower gears it adds up to even more torque above the standard. I believe the module has lowered fuel consumption while towing by about 5 litres per hundred kilometers, although I don't think it makes any difference unless the van is hooked up. It will be interesting to see how well the beefed-up LC tows the relatively heavy Bushtracker which will probably come in at 2,900 kg tare and 3,500 kg loaded.

While visiting Bushtracker in December we had Sound In Motion (Nambour) add in a twelve pin plug wired to Bushtracker specifications (see plug photo above). They also wired the rear view camera system into the twelve pin plug. In addition, I asked them to fit plug and play connectors to the driving lights so that I can remove them when not needed. I believe they cut down the air flow over the intercooler and add to the fuel consumption so I will only refit them just prior to driving long country distances at night.  

I've just completed what I believe will be the final modification prior to picking up the Bushtracker. This is the installation of a set of Drifter drawers and a drop down slide for the Engel fridge. As part of the package I also installed a cargo barrier that will stop any objects from being flung around while allowing us to tie down the internal load if we need to.

The LC has several storage pockets that are useful. This one on the tail gate for example carries a medical kit, a tyre gauge and the remote cable and control for the Warn winch.
However, for off road camping I think I will need to be further prepared so there are several other items including tools that I think need to be taken along and stored.

I chose Drifter for this additional storage after looking at a range of options. Price ($2,400), weight, durability, finish, personalised service and the smooth flow of the drawers on Teflon strips all appealed. So too did the fact that the unit came with a portable table that we will trial as our main camp table, alleviating what has long been a storage nuisance.

The drifter storage system installed with the MSA 4x4 D40 drop slide and the cargo barrier. The cargo barrier was suspended from both the former grab handles and a bracket extending from where the seat was secured. It tended to rattle from side to side and create noise. However, two brackets from the lower fitting each screwed to the drawer frame with three long wood screws cut down both movement and noise. 

The slide-out/down fridge provides easy access to food and beverages as well as securing the fridge inside the car.  The slide is heavy and robust but it will be very handy. Having an additional fridge adds capacity for fridge or freezer when camping. However, its main purpose is to provide cold storage when we are away from the van.

I chose to add a divider between the fridge and luggage compartment so that the fridge would always be free to slide out. I've secured the wooden carpet covered divider with screws to the base, with a customised metal clamp onto the cargo rack. I stopped the rattle of mettle on mettle by squeezing silicone below and above the clamp and letting it set.

Note the wing installation and the side covers on the drawers are customised to the shape of the LC then covered in carpet supplied by Drifter. They fit neatly without being screwed into place and the handles allow easy access and replacement.  

Note that the table sits above the right hand drawer and slides out independently. It pulls out easily and its leg height is adjustable. It seems to be a good solid table and is well tucked away while being easily accessible.

Installation of the total package took a couple of days. We had to remove the two rear seats, with much of the fitting re-utilising both the seat bolts and their location nuts. We also had to remove the rear grab handles. All of these are now stored for reinstallation if needed at a later date. However, the complexity and time it took for installation militate against any interchange between modes, at least on any regular basis. The kids will have to use our shopping trolly car when they come over next time.

The side wings, made to measure with the fridge 240volt connection cut into the bed. Note the addition of the handle, one of four to give control over boards that are fitted but not screwed down. This work was fiddly but rewarding. We used a large can of spray on Selleys Kwik Grip contact glue to secure the carpet, which worked a treat.

The side areas give additional storage. In this case, this is where I keep the Lightforce driving lights when not attached to the bull bar. You have to watch the fridge cable which tends to get caught amongst the fridge slide mechanism. On the other side I can stored various umbrellas and the large UHF aerial, all of which used to rattle around in the back of the car.

I've loaded up the drawers with all and sundry. All the car/van lubricating and cleaning gear, my tools, fire extinguishers, a trailer mate jack and other sundry items are all locked away but easily accessible. In particular, I won't have to have this stuff floating around in the cargo hold of the van. It is all secured in the car and I can access it whether at camp, on the road or at home. The deep drawers seem to take the weight easily and still slide well. Access is easy from the side of the rear tray so it doesn't matter if things are down the back.


The weight of the car with the storage, a full fuel tank and me in it is now a little over 3,300 kg. This means I can legally carry only about 200 kg of other gear which might include camping equipment and water all of which we will need if we are away from the BT for any time. I'll sure need all of the 3,500 Kg GVM the car now has.

Interestingly, the new GVM (3,500 kg) and the towing capacity of the LC (3,500 kg) together (7,000 kg) exceed the published Gross Combined Mass (6,800 kg) set by Toyota. I'm yet to resolve this anomaly and hopefully won't ever have to discuss it with a motor vehicle inspector. The Internet indicates that GCM is not a legislated requirement but is set as a guide by the manufacturer. If so, it probably reflects the conservative approach Toyota takes to a tug that is solid enough to go offroad into the Australian bush but generally knocks around in cities.  It might test my bush lawyer skills if we are challenged by an inspector.

The Bushtracker being Built

Allison and I spent a few days last week (8 to 14 December) on the Sunshine Coast during which we visited the Bushtracker factory to check out building progress on our caravan. Having a little more to put in the van than we could take in one LC load, we drove up (about 2500 km each way - 2.5 days up and the same back) and dropped off some gear in a nearby Kunda Park storage locker, ready for kitting out the van on delivery. 

We did the initial design work for the caravan with Philip on 28 August 2013 and have continued modifying the design since then. We signed off on a pre-final production design on 28 October and production moved ahead under Matt's supervision. By the time of our visit, the chassis had been constructed, the frame built and installed on the chassis with the floor in place, the cabinetry installed and the van was in electrical fitting having the 240, 12 volt and solar systems installed.

The following few photos were taken around the factory during our visit. While they are not of our van, they show the stages prior to the electrical fit-out.

Each frame section is built to the specific design of the particular van. I'm told that the welder has had long experience at building aluminum frames and both their construction quality and design make the Bushtracker a very solid off road van.

The frame sections are welded together and bolted onto the chassis prior to installation of the cabinetry. The floor is high grade marine ply with all exposed surfaces treated with three coats of resin to prevent any water ingress.  The distinctive nose cone, under which the spare wheels and gas bottles are later located, is a further distinguishing feature of Bushtracker. With the high internal under bed storage, the queen size island bed sits neatly into the nose cone, high off the floor.

Each component of the van is custom made according to the production schedule. However, some elements of design are ongoing. For example, we made some changes this week as a result of the visit. In our original design we were not going to install satellite TV equipment although we had planned for the pre-wiring and roof bracing needed if any future buyer wanted to do so. As it turns out, for $1500 there is now a system with a lightweight external (plug in) satellite dish that folds up into a relatively small bag which can be stored in the hold. So we have asked for that system to be installed as well as including the future wiring and bracing provisions for someone who might want to install the $6,500 oyster rooftop satellite dish. 

The Simplicity suspension is heavy duty in build, a Bushtracker feature. Note the high wheel arch boxes that allow each wheel substantial vertical movement over rugged ground. The nature of the suspension means that the weight of the van is always evenly distributed over the wheels, even when one is on a different plane to the other. In our case, we have opted for 12 inch commercial brakes and the wheels and tyres will be the same 18 inch setup as the LC so we will have three spares.

The high quality 6 inch chassis is built off site by a specialist chassis maker who also builds for the army. It is heavy duty in construction, dip galvanised and treated later with a special rust preventative under the van itself. 

The upswept tail allows for tight uphill situations such as three point turns in the bush. While it cuts out some internal storage space and militates against external rear storage, including placing the spare wheels at the back, the unique off road Bushtracker shape distinguishes the purpose of the van. It aids in the principle of keeping the weight over the wheels and a little toward the front, preventing what is known as harmonic motion on corrugated roads.

 The following photos were taken inside and outside of our van during its electrical fit-out.

 This is our actual van. It is fitted with temporary wheels during construction to ensure that what we get in the end is brand new.

The kitchen is on left of photo and the cafe seating on the right, with the bed raised. Note the bedside storage lockers. We have also opted to arrange for the table of the cafe seating to be able to be lowered and used when necessary as the base of a single bed. The mattress inserts will be used as bolsters on the main bed.

This is the kitchen area of the van showing the amount of storage under the bench. We have opted for a pot drawer rather than a microwave but you can see where the 240 volt PP will be installed at the back of the drawer in case we decide on a microwave later. Note that the high wheel arch boxes take up much of the space in the lower cupboards, which will be accessed mainly by locker doors. The area under the sink (with the external AV locker cutout at the rear) will have a top-to-bottom door while the other spaces will be drawers. The Swift stove with grill and oven goes in the large space to the left of the photo.

Inside the large fridge space with the cutout for the upper fridge vent. We inquired about insulating this space but it was explained that the compressor fridge needs to draw air from around the space and its efficiency would be severely reduced if it were insulated. This is in contrast to the requirements of the three way absorption fridge in our last van that would have benefited from such insulation. 

.

This is the ensuite vanity. Note that the lower section of the vanity is sloped as it corresponds with the swept up tail of the van. The lower sections will have locker doors while the upper sections will have drawers.

This is a front on picture of the lower storage hold inside the shower recess. The shower walls and floor are to be completely covered in fibre glass with water proof doors to be added to the storage lockers. Note that the lower section of the locker is sloped as it corresponds with the swept up tail of the van. 

This is the upper section of the shower recess with its storage locker, and the right hand storage locker in the ensuite, to be used for toiletries. Note the window to the shower and the wiring above for the 12 volt fan. We have added 50mm to the shower to get the shelf and sufficient space to wash our hair.

This is the storage unit to the left of the ensuite for towels and sheets etc. The large window over the toilet  provides venting without the need for a forced fan on the roof.

This is the front of the van showing the high storage locker or 'hold' under the queen size island bed which is raised on hydraulic shockers. You can also see the structure of the three large storage drawers, the compartment for the Dometic 5 kg front loader washing machine and a side compartment on the near side for further storage, accessed above and at the side. There is no foot locker on the near side because we have installed a small pull out external BBQ that can be hooked up to the van's gas supply.

This is one of the under floor storage lockers on the off side beside the bed, with the bedside storage to the left top of picture. You can also get a glimpse of the floor covering the Alli has selected.

This is a nose cone view of our van. You get an idea of the distinctive Bushtracker shape as well as the size of the windows and storage door. You also get an idea of the quality of the electrical work noting that the 240 and 12 volt wires all go through pre-drilled holes in the frame into which  grommets are placed to ensure the wires don't rub and short on the frame. All electrical work is set out carefully to the pre-arranged plan.

Note the wooden backing plate for the external clearance light, as well as its wiring that has been roughed in.

This shows a glimpse inside the van door, showing the fridge space, pantry and under fridge drawer space. The pantry will be mainly drawers with a locker at the bottom. Under the fridge is a large drawer. On the outside of the van you can see the kitchen window frame as well as the frame for the external electrical locker. The roughed in 12 volt wire near the door is for the lighted grab handle. To the left inside of the door is the locker for the water tank manifolds so that we can choose which tank to use. It is important to use water from the outer tanks first for balance.

The A frame and its nearby wall frame are braced to take the load of the two heavy 18 inch spare wheels and the gas cylinders, all sitting under the nose cone. The gas plumber has left the gas piping for the next stage of his work.

This is the off side rear of the van showing the upswept tail, the locker for the hot water system, the locker for the toilet cassette and the lower fridge vent. The through pole storage locker will be installed in the rear triangle section with a screw on lid exposed both sides of the van.

At the top of the rear of the van is a tail light and the reversing camera. These wooden backing plates are ready to take each.

The hole in the back of the van is the frame for the external shower.

 

The shot above shows both the solid nature of the chassis and suspension as well as the rust proofing coat that has been applied under the van. The shot to the right shows the main electrical board, being built with pride by a skilled and experienced craftsman who has worked for the company for many years. He pointed out that the company employed highly skilled and experienced people in each trade to ensure the build quality of the vans.

The under bed storage area, known I think as the cargo hold, is accessed from both near and off sides through extra large doors and from inside by raising the bed. The cargo hold houses the electrical fuse box, battery charger, inverter, solar regulator, etc on the main board. The lithium battery goes in the white box at the electrician's shoulder. Access from the bedside lockers allows you to move gear if it has shifted and is blocking the door from opening. Later, at the back of the electrician, will be installed the water tank filling manifolds.

The front off-side over head cupboard is used to house the circuit breakers, as well as the DVD/Radio, solar and battery charge indicators, hot water heater switch, and the VAST satellite box.

This last picture isn't of our van but I thought I would take a photo of one having the skin installed. Note how well the thick insulation is fitted tightly to the frame. Our van is in the background.

So our caravan is well on the way. We have opted for an Air Command Cormorant roof top air conditioner, 4 solar panels and 4 water tanks (one potable).  We may add a couple more tanks when we have our first service.

The van will have external speakers with an external remote, a 24 inch LED TV that can go inside or outside, bluetooth to the stereo so we can play music from our I Phones, extra power points inside and out, and the outdoor shower. It will also have a diesel heater for the winter and a large storage box on the extended A Frame for the generator and three jerry cans. 

We have also selected the A and E electric roll out awning. The seating is brown leather and the cupboard doors are a flat finish, with a sliver splash back to the kitchen bench. 

With Bushtracker about to close up for the Christmas break, it is unlikely that van will be ready before early February 2014. We will not rush anyone, so we will simply wait patiently until we get the call.

Progress in Preparing for the Bushtracker

This wait while having the caravan built can only be called ‘frustrating’. It isn’t Bushtracker’s fault in terms of building delays, although having all of my emails to anyone in the company vetted and passed on certainly cuts the level of communication between the client and those doing the work.

My van is now up to the production stage, but I don’t know where production itself is up to. During the design stage, I had frequent and fruitful email exchanges with Philip to clarify points and make decisions. Since then, although I’ve sent emails off to find out when would be a suitable time to visit and to ask for progress photos that I believe Bushtracker take, I have had no real contact. I did ask Matt for reassurance about an issue of rotting floorboards that was raised on the BOG forum and got a quick and satisfactory reply from Steve, most of which I posted as part of the BOG discussion. In the end a phone call to Matt indicated where the van was up to and when would be a suitable time to visit. Obviously phone contact is preferable at times.

The various Bushtracker associated websites  are a wealth of information, allowing you to interact with other like minded people. I find the BOG website less intimidating than the forum. Some of the replies from the company on matters raised in the forum are a little less than diplomatic, often impacting people who are inexperienced and simply ask for advice. However, the technical discussions on both the forum and the BOG site are great. I tend to log in daily and either follow BOG posts in which I’ve become involved, as well as new posts, or I view all posts since my last visit to the forum and read everything that has been posted recently.

Trawling through back posts on both sites has been fascinating and very worthwhile. This morning, after reading posts and getting in touch with Sun Buster as recommended in one post, I received a ‘caravan weight machine’ to measure both LC and caravan gross weights.  Not essential, but certainly reassuring when so much discussion revolves around avoiding being overloaded in either van or LC. I was chased off what I thought was a public weighbridge the other day when I was attempting to measure the LC weight. The new machine will avoid such embarrassment.

I’ve read about batteries and their maintenance, although with lithium batteries there is less information on the forums and I still feel ill informed. I’ve read members’ experiences with air conditioners that caused me to change my mind from Dometic to Air Command Cormorant. I’ve sought and received advice on where to camp around the Sunshine Coast when we pick up the van, prior to the first service. As a result of information on the BOG site, I’m currently researching CGear products related to shade cloth and their ‘multimat’ that keeps sand and dust below the mat when parked up for a while.

In addition, Allison and I have been through all of our caravan gear and decided what will be taken up to the van and what wont. The gear all sits in the garage blocking space for the LC to be put away. We will make a visit to the Bushtracker factory sometime in the production process, hopefully mid December, both to review and fine-tune anything if necessary and to take one load up to the Sunshine Coast for storage until we pick up the van.

This will mean we will have a fair bit of space in the LC when we travel in January to pick the van up. However, I have ordered a set of Drifter drawers with a fridge slide that will take up some of the space. While somewhat more cumbersome than the clear rear area of the LC, the drawers will organise and tie down the LC storage. They also will make sure things don’t damage the back of the seats as happened on the Arkaroola trip.  I’ll have to pull the extra rear seats out prior to fitting the drawers but, as the kids are coming for Christmas, this can wait.

All this is filling in time while we wait for the van. I know it will be the best.  I know it will open up a new world of exploration. And, like the kid at heart I am, I can’t wait to get going. It will be a great after Christmas present for both of us, won’t it?

A visit to Arkaroola in the Flinders Ranges SA

As we don't yet have our Bushtracker caravan, we decided to take up a Travel Auction and bid for a few days at Arkaroola in the northern Flinders Ranges of SA. After a six hour trip from Adelaide through Burra and Orroroo, including a beer at the Parachilna pub with Jane and a night at Copley caravan park, we headed for Arkaroola on the dirt. Great road and well graded at the time. Very easy for a van if we had one - even an on-road van.

Arkaroola Village has all styles of accommodation, including caravan park and camping. We stayed in a basic motel suite for three nights at $90 per night including continental breaky. Great value - half price from the travel auction.  Dining room for dinner was very good and general facilities more than you would expect in an isolated area.  Backpacker and regular staff quite friendly, informative and committed. Fuel and supplies available.

The Ridge Top tour ($120 each) was excellent, showing us the full range of scenery, geology, plants and animals with an expert commentary by a geologist who was passionate about the area. The marvellous rock formations, the folding, faulting, volcanic activity and metamorphosis over millions of years and the long term wearing down of the rocks were all out there for us to see in one short 4 wheel drive trip. One stone the guide picked up was formed over four kilometers below the surface. Lots of long term erosion had revealed it on the surface. Another formation was formerly like Rotorua with its steaming mud, but was now a barren hill of fissures eroding in the sun. Great four wheel drive challenges in a few spots, including up Skennars lookout to a view across Lake Frome and beyond.

The landscape is amazing. A geosyncline from Gondwana times, the area was filled in over time with kilometers of sea floor detritus, building up to such a weight that it forced down the area around it to below current sea level. Large surrounding salt lakes like Lake Frome remain as evidence of internal drainage patterns. Fossils of the earliest life on earth were found by Reg Sprigg, the original owner of the conservation park, forcing geologists to change their description of geological time lines involving life.

Following sedimentation, the area was subject to the most amazing geological forces of uplift, tilt, volcanic intrusions, glaciers, heat and weight so that almost every type of geological outcome is evident in the rocks. After subsequent millions of years of erosion, what is left is a kaleidoscope of landforms, all within sight and readily accessible by bushwalking or 4 wheel drive track.

'Dry as' at the present, - probably going into the next four years of drought. But over the last few years it has been relatively wet - more than the usual glass of rain for the year - and there is a lot of new vegetation with a green tinge that is a little unusual. On our 4 wheel drive tracks we spotted bush banana, orange, curry plant and lots of new acacias and calliteris pines. Rock sida was growing to a meter when it normally stays as a little bush. Desert rose is in flower. White mullas have been flowering for several months and don't look like dying off.

Animals aplenty. Old man emus with their chicks. Euros in abundance along the creeks and the occasional skittish Yellow Footed Rock Wallabies, especially around the waterholes and by the camp at night. Big reds further out on the high open flat lands of the nearby national park. Very few reptiles, but lots of goats near the national park - a cause for some concern in the conservation area. Some flights of Port Lincoln parrot and plenty of smaller bush birds.

 
The area is privately owned but the bulk has been handed to a foundation to protect its future. Mining has been proscribed by law although the area has a long modern history of mineral exploration and some marginal exploitation. Mining tracks abound in the southern section, although the north is only accessible by foot.  Originally 'no man's land' between various marginal sheep stations, it was indeed fortunate that Reg Sprigg was able to buy up the unwanted land and conserve it for present visitors.

Well worth the visit to see some of the most unique landscapes in this unique and ancient continent. It is amazing that more people don't realise the wealth, beauty and tourism riches that are for all to enjoy in Arkaroola. We will certainly take the van back there when we have the chance.