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 Princess Dorothy 

Princess Dorothy#

A custom overlanding/#vanlife vehicle for expeditions and adventures. But mostly hauling plywood.

Having a box truck was a weird decade long dream of mine, and I finally accumulated enough reasons to justify getting one. The idea was to build something that could both maintain truck-ness (haul large quantities of things, full plywood sheets, etc), as well as serve as a long-duration expedition vehicle for doing dumb things in dumb places.

This page is mostly about the build-out process and some snippets of it in use.

Finished Tour#

Why save the best for last?

RV windows, bailout board, roof ladder, external shower, pull-out toilet tank, and charging port
RV windows, bailout board, roof ladder, external shower, pull-out toilet tank, and charging port
Comms mast and RV windows
Comms mast and RV windows
How it started
How it started
Rear partially folded out. Couch folds down into a bed. Rear doors have folding rear tables.
Rear partially folded out. Couch folds down into a bed. Rear doors have folding rear tables.
Rear partially folded
Rear partially folded
Cargo mode. Rear fully tucked, with couch/bed folds flat against the wall
Cargo mode. Rear fully tucked, with couch/bed folds flat against the wall
Cargo-mode full of cargo (batteries for another project)
Cargo-mode full of cargo (batteries for another project)
900w of folding roof solar
900w of folding roof solar
Folding solar extended
Folding solar extended
Dismountable rooftop Starlink Gen3
Dismountable rooftop Starlink Gen3
Hot-water shower and flushing toilet
Hot-water shower and flushing toilet
12v Air Conditioning
12v Air Conditioning
One of two 12v-450ah LiFePo4 (Lithium-Iron) battery packs
One of two 12v-450ah LiFePo4 (Lithium-Iron) battery packs
Hot water tank and water filtration system. 30+ gal potable tank.
Hot water tank and water filtration system. 30+ gal potable tank.

Need to add back initial build photos -#

Upgrade Package#

Some hard lessons were learned from operating the first version, and so some upgrades were made:

  • Wet wipes only get you so far, you need a real shower for any length of time,
  • The less you have to do to clear a toilet, the better,
  • Well-insulated boxes also get really hot really fast without good ventilation/air conditioning,
  • Starlink was a game-changer, especially with the places Dorothy was going,
  • Box trucks and their leaf springs are extra-wobbly. I needed to reduce the top weight by using lighter panels on the roof.
  • With so many important systems on the roof, a service ladder was needed,
  • Too many RV systems are 12v. I was going to need to move the batteries from 48v to to 12v (and all the copper that entailed).
  • Minimize the amount of re-adjusting things you need to do while on the go.
  • Less cabinet doors
  • Fridges were permanent, and needed and permanent home
  • Microwave was sorely missed. You can only stove-top so much. Turns out microwave/convection oven combos are a thing!
Running refrigerant lines
Running refrigerant lines
Drawing vacuum and adding refrigerant
Drawing vacuum and adding refrigerant
Working air conditioning
Working air conditioning
Re-sized and re-welded folding couch-bed frame
Re-sized and re-welded folding couch-bed frame
Shower pan re-sized, base built, and mounted the flushing cassette toilet
Shower pan re-sized, base built, and mounted the flushing cassette toilet
My favorite metal supply shop refuses to do (even paid) cuts, and insists I "Use saw, save money!"
My favorite metal supply shop refuses to do (even paid) cuts, and insists I "Use saw, save money!"
Flexible panels needed bracing/stiffening/wind-shielding. Even with the added aluminum, the panels were still 3x lighter than traditional panels.
Flexible panels needed bracing/stiffening/wind-shielding. Even with the added aluminum, the panels were still 3x lighter than traditional panels.
Fully mounted
Fully mounted
Had a visitor!
Had a visitor!
3D Printed Gen2 Starlink mount, fused with JB-Weld Plastic
3D Printed Gen2 Starlink mount, fused with JB-Weld Plastic
Coated in bondo-acetone slurry: https://youtu.be/CxjqQLAy5TU
Coated in bondo-acetone slurry: https://youtu.be/CxjqQLAy5TU
And then sanded down and painted
And then sanded down and painted
Threaded heat-set inserts for the...
Threaded heat-set inserts for the...
... designed and printed spring-clips, so the Gen2 starlink could be popped in/out as needed.
... designed and printed spring-clips, so the Gen2 starlink could be popped in/out as needed.
Finished Gen2 Starlink mount
Finished Gen2 Starlink mount
Ended up scraping it once Gen3 came out.  The field-of-view upgrade really improved flat-mount use. It's already-flatness also let me quickly whip up a 2020 extrusion and laser-cut Delrin mount. I was at least able to reuse the aluminum roof-mount brackets.
Ended up scraping it once Gen3 came out. The field-of-view upgrade really improved flat-mount use. It's already-flatness also let me quickly whip up a 2020 extrusion and laser-cut Delrin mount. I was at least able to reuse the aluminum roof-mount brackets.
Sharp cabinet corners proved a hazzard
Sharp cabinet corners proved a hazzard
Sliding front cabin doors, magnetically latched
Sliding front cabin doors, magnetically latched
Rear-view camera
Rear-view camera
Rear space heater
Rear space heater
Alarm System
Alarm System