SmartPlug/Aux Solar/Exterior Plug

TLDR: We designed, had fabricated, and installed some custom panels for our shore power, aux solar, and exterior outlets. We highly recommend this approach.

On Van 1.0 we installed a standard RV shorepower plug on the driver side of the van. It worked fine, but it does involve putting a hole in the side of the van. It also got damaged by an uncontrolled rear door opening while the cover was flipped up. For Van 2.0, we have an opportunity to improve.

The transit has two rectangular ports underneath the bumper structure. They are easy to get to, and out of the way of weather and doors. DaveInSeattle made brilliant use of one of these ports to install his shorepower and aux solar connection. We decided to do the same.

Dave's shorepower approach Dave's approach. Image credit: Dave

We'll be using a SmartPlug for our shorepower connection. It allegedly improves on the standard screw lock plugs. We'll see. We opted for the shiny stainless variant. Also like Dave, we'll use the same port for our aux solar connection (for a future moveable, ground based array). We opted for this SAE power socket.

Sophia spent some quality time crawling around under the van with cardboard and calipers. She figured out a way to arrange the Smartplug, the power socket, and four future plusnuts in spite of Ford's constraints. This freed up the second port for an exterior plug (more later).

template Cardboard is the true van conversion hero.

Once we were satisfied that everything fit, I finished the design in Fusion 360.

shorepower The smartplug/aux solar dxf is here.

While I was at it, I when ahead and designed a second plate for the adjacent rectangular port that will house an exterior plug, now that I knew it wouldn't be needed for the aux solar connection. This was much more straight forward. Update: Oops, didn't take the time to do a physical sanity check, and there is an interference with the tow hitch stucture...so there will be another design iteration. Repeat after me: All models are wrong. Don't confuse the map for the territory. Update: Redesigned to avoid tow hitch interference and reduce number of fastening points.

outlet The outlet plate dxf is here.

We sent the designs off to sendcutsend. We ordered them in 1/8 aluminum which should be plenty stout and corrosion resistant. The total for both plates was $19 even. Not bad.

We received the plates and did a fit check. There is, as was expected an interference on the outlet plate between the plusnut and the hitch structure. We'll fix that and order a new plate. The shorepower plate is fire.

delivery Pretty much my favorite company to get packages from.

front Front view with components.

back Back view with components.

fitcheck Fitup in place.

We ordered some adhesive neoprene sheet from amazon and added that to the backside to act as a waterproof gasket.

Other Useful Things

Its always great when you can find dimensioned drawings from manuafacturers!

outlet

smartplug

Timeline

Note, this doesn't reflect full time effort. It's mostly evenings and partial days, limited by other work, life, etc.

  • Templated/designed (Mon 12-13-2021)
  • Made drawings and placed order (Tue 12-14-2021)
  • Received plates and fit check (Sat 12-17-2021)
  • Added adhesive foam to shorepower plate (Tue 12-28-2021)
  • Drilled, painted, and primed holes for plusnuts (Thur 1-27-2022)
  • Wired and installed smartplug and exterior outlet (Fri 1-28-2022)