According to recent research, interest in overland rigs has grown 2,000 percent between 2016 and 2023, driven in large part by Western U.S. states. However, many people are still unsure as to how to build an overland rig that is equipped with reliable off-grid power, which is essential to maximize freedom and flexibility, and to venture off the beaten path.
Whether you're traversing remote landscapes or camping for days at a time, having a dependable source of energy ensures that your vehicle and essential systems keep running smoothly. Here's a comprehensive guide on how to build an overland rig with reliable off-grid power.
1. Assess Your Power Needs
Before selecting any power solutions, the first step is understanding what electrical devices and systems you will be powering. Typical off-grid setups include:
- Fridge/Freezer: A compact fridge or freezer to keep food fresh.
- Lighting: LED lights inside and outside the vehicle.
- Charging Devices: Phones, tablets, cameras, GPS, and radios.
- Water Pump: For sink or shower setups.
- Heating/Cooling: Small fans or heating elements.
- Cooking Equipment: If using induction or electric stoves.
To assess your power needs, make a list of all the devices you'll be using, their wattage, and estimated usage time per day. You can also use this free tool to help determine the size of the battery bank and charging system required.
2. Choose a Reliable Battery Setup
Your overland rig’s power system will rely on a robust battery setup. The two most common options are:
- Lead-Acid Batteries: Although these have the lowest upfront price point, they have significant limitations in terms of lifespan, depth of discharge, and weight.
- Lithium-Ion (LiFePO4) Batteries: Lithium batteries are significantly lighter, offer deeper discharge, have a longer lifespan, and charge more efficiently. They are ideal for off-grid applications where reliability and power storage are paramount.
Choose batteries with enough capacity to meet your daily power consumption and reserve enough energy for overcast days or long drives without recharging. Capacity is measured in amp-hours (Ah) or watt-hours (Wh), and lithium-ion batteries generally provide the best weight-to-power ratio.
Lithium batteries such as the RELiON RB52 and the RB100 offer abundant power in a small size that last ten times longer than their lead-acid battery counterparts. For those with larger power and energy needs they can take on the go, the Outlaw 1072S Portable Power Station allows for multiple appliances and electronics to all be charged and powered from a single battery - all without the noise and fumes that alternatives like a fossil-fuel powered generator come with. A long-time overlander, Corey Whitaker uses two RELiON InSight 12V-LT (Low Temperature) 120Ah batteries, which are known for withstanding conditions and locations that are isolated and extreme.
3. Incorporate Solar Power
For a truly off-grid overland rig, solar power is one of the most sustainable and reliable ways to keep your batteries charged, especially if you plan to be in remote locations for extended periods. Here's how to integrate solar into your setup:
- Solar Panels: Portable or roof-mounted solar panels are your primary source of renewable energy. Portable panels allow flexibility in positioning, while roof-mounted panels offer convenience.
- Solar Charge Controller: A charge controller regulates the voltage and current coming from the solar panels to prevent overcharging and damage to your battery bank. MPPT (Maximum Power Point Tracking) charge controllers are more efficient and recommended for solar systems.
How Much Solar Power Do You Need?
The size of your solar array depends on your energy consumption. As a rule of thumb, a 100W panel can produce 300-600 watt-hours per day depending on sunlight, so plan accordingly.
4. Dual-Battery Systems
Many overlanders opt for a dual-battery system, which separates the vehicle’s starter battery from the auxiliary battery system. This setup ensures that you always have a dedicated battery for your essential rig systems without draining the one needed to start the engine.
Should I Use Battery Isolators or DC-DC Chargers
A battery isolator ensures that your starter battery is protected and prioritizes charging for your auxiliary battery while driving. Alternatively, a DC-DC charger is more efficient, especially when using lithium-ion batteries, as it charges them optimally even during low engine output.
5. Inverter for AC Power
To power AC devices, like laptops or other household electronics, you'll need a power inverter. The inverter converts DC (direct current) from your battery into AC (alternating current). Choose an inverter that matches the wattage of the devices you intend to use and has built-in protection for voltage fluctuations.
Pure Sine Wave Inverter
For sensitive electronics like laptops or camera gear, a pure sine wave inverter is ideal as it provides clean, stable power.
7. Monitor and Manage Power Usage
Proper management of your off-grid power system is key to long-term reliability. If your battery system does not already come with one, you should install a battery monitor that tracks your energy consumption, battery levels, and charging status. This gives you real-time data on power use and helps prevent running your batteries too low. Modern systems often integrate with smartphone apps, giving you insights and control over your power system remotely.
RELiON lithium batteries all come with an advanced and easy to use smart Battery Management System (BMS), which protects the cells from getting damaged — most commonly from over or under-voltage, over current, high temperature or external short-circuiting. The BMS will shut off the battery to protect the cells from unsafe operating conditions.
8. Ensure Safety and Durability
Safety is paramount when building an off-grid power system. Ensure that all components, including batteries, inverters, and charge controllers, are installed with proper fuses, wiring, and ventilation.
Waterproofing and Dust-proofing
Since overland rigs encounter harsh environments, ensure that your electrical components are well-protected from the elements. Waterproof enclosures and dustproof covers are essential, especially for roof-mounted solar panels and wiring.
9. Test Your Setup Before Heading Out
Once your power system is installed, it's critical to test it in a controlled environment before heading out on long trips. Run your devices, test charging cycles, and observe how long your system can operate without external input. This will help you identify any issues and make adjustments before you're out in the wilderness.
10. Plan for Upgrades
Technology evolves quickly, and you may want to expand your system as your needs grow. Design your rig with future upgrades in mind, ensuring there’s room to add more batteries, panels, or inverters as needed.
Building an overland rig with reliable off-grid power allows you to explore remote areas with confidence and independence. By carefully assessing your power needs, selecting the right battery system, and integrating solar and backup solutions, you can create a robust power setup that will keep you going no matter where your adventure takes you. If you have any questions about how to build a reliable off-grid power system into your overland rig, get in touch with a technical expert at RELiON.