"All of my lighting is LED, and everything is working off 12 volts" Marshall said. "I did want to have the added luxury of having a 110 AC system as well. The only appliance that I have that runs off of AC is the microwave. The four large AGM batteries that I have on this system are charged solely through the solar panels." On the topic of panels, he plans to expand the solar array. "I have a little over 500 watts on the roof now, and in the summer, that is more than enough. However, during the winter, the sun is far lower in the horizon, making the angle of incidence much lower as well. This lower angle drastically reduces the solar panels' efficiency. To date, the vehicle has never received a single electron from any other source other than the solar. But by expanding the array, I will also shorten the recovery cycle time for the system."
The expedition camper started as a Gichner military-surplus box, which Marshall sandblasted, then rubberized the roof. Software typically meant for designing kitchens was utilized to blueprint the camper's interior layout, including areas for the bed, kitchen, and shower/toilet. Cabinets came from Home Depot, while items such as doors and windows, air conditioning, and appliances were found on eBay. He also built storage lockers accessible from the exterior.
Comfort and self-sufficiency while overlanding meant adding a three-way fridge; shower/cassette toilet combo; a kitchen with a sink, stove, and microwave; 84-gallon water tank; water heater; bed; entertainment system; flat-screen TV; AGM battery bank; 7,000-watt inverter; cell phone booster and antenna tower; LED lighting; and sofa. GPS is handled by Avenza and an iPad.
Having a high-clearance vehicle meant the camper access would also be up high. "I have seen some builds that simply used a ladder to gain access. However, I felt this would be problematic." The door opens outward, so standing high enough on the ladder to reach the door would mean being in the way of the door. "I decided I would need some type of landing to stand on while opening the door," Marshall said. "The porch was simply an expansion of this idea and the inspiration to build a full patio off the side of the camper." The 4-foot-wide porch is aluminum and decked in hard pine and operates via button-based hydraulics/linear actuators. Three receiver-hitch-style pieces are on the side of the box to hold the patio.
2005 Mercedes-Benz Unimog U500 Specifications
Owner: John Marshall
Stomping grounds: Moab, Utah
Build time: 2 years
Unimog U500 Drivetrain
Engine: Mercedes-Benz OM906LA 6.4L inline-six
Transmission: Mercedes-Benz 8-spd EPS manual
Transfer case: Integrated with transmission
Low range ratio: 2.71:1
Crawl ratio: 3,165:1
Front axle/differential: Model 737.591 portal axle/locking differential
Rear axle/differential: Model 747.591 portal axle/locking differential
Unimog U500 Suspension
Front: Coil springs, control arms, factory hydraulic shocks, steering stabilizer, pitman arm
Rear: Coil springs, trailing arms, factory hydraulic shocks
Unimog U500 Wheels And Tires
Tires: 395/85R20 Goodyear MV/T
Wheels: 20x10 aluminum Hutchinson MRAP
Unimog U500 Camper And Accessories
Cool stuff: Steel receiver hitch, PTO, lightbar
Camper: Gichner box, rooftop solar panels, SMK Solar controller, 7,000-watt inverter, AGM battery bank, Carefree of Colorado awning, air conditioning, couch, custom deck/porch, entertainment system/TV, custom storage lockers, recessed lighting, shower, cassette toilet, kitchen with propane stove, woodgrain ceiling, Canyon Coolers cooler