2004 Model Trek Test

There are a number of innovations for the 2004 models which required thorough testing. In addition to bench testing and local travel, a complete 4,500km Trek was planned.

The route chosen was suggested by a customer for variety of test conditions:

• From Ballina, we went straight to Bourke
• up through Tibooburra and Sturt National Park to Camerons Corner
• up the Bore track to Innamincka on the eastern edge of Strzelecki Desert
• up Walkers Crossing on the edge of Sturt Stony Desert to Birdsville Track
• Up the Birdsville Track to Birdsville
• Then east to Windorah
• Then south to Lake Bindegolly National Park near Thargomindah
• Then east to St George and back on to Ballina

The route from east of Innamincka to Birdsville followed closely the “Burke & Wills” route of 1860-1861; so we read “The Dig Tree: The Extraordinary Story of the Burke and Wills Expedition” by Sarah Murgatroyd to set the scene for the main part of the trek.

The trek took 12 days with only 3 of these on powered sites.

For the testing, we took a 2002 Model Kimberley Camper Trailer, a 2003 Kimberley Mariner and a 2004 Model Prototype with all the proposed innovations on the one Camper.
We were heavily loaded with the following extras:

• 3.7m Stessl Edge Tracker Boat
• 20Hp Honda 4 stroke Outboard
• Honda 10EUi
• Honda 20EUi
• Christie 80A Battery Charger with Honda 3Hp
• Quirks 100W Solarport
• Unisolar collapsible Solarpak 2 x 30W
• Unisolar flat 32W panel
• 73 Liter Autofridge set as a freezer
• 80 Liter Waeco set as a fridge
• 3 portable temperature dataloggers with remote computer interface
• Energy diagnostic power unit based on Victron BMV501 and Plasmatronics PL20 with remote computer interface
• Orbital Gell 80A batteries
• Exide ED 10 AGM batteries
• Exide N130 Flooded batteries

The crew consisted of 9 adults and 7 children aged from 3 to 7, with our 3 year old having broken his arm the day before the trip!

To test the suspension for the new leaf spring Escape model:

• we loaded 205kgs in the front Gullwing Storage Pak with all the generators, a total of 6 gerry cans and the Autofridge fully loaded.
• we videotaped the suspension travel over difficult terrain at low and high road speed; then we replayed in slow motion
• we selectively hit some large bumps and potholes at road speed
• we traveled on corrugations at high speed (until my wife threatened divorce)
• we measured the height of the Camper on the flat before & after the trip
• Finally, we traveled with a glass Bodum 8 cup coffee plunger in the kitchen drawer unwrapped and loose behind the electric water pump – it traveled the entire journey in tact

The suspension passed every test.

To test the new Gullwing Storage Pak for dust proof:

Firstly, you need to be aware of the greatest difficulty in housing refrigerators/freezers in closed areas is the need for ventilation to keep the temperature down so that the fridge/freezer will operate efficiently.
We setup the freezer in the new Gullwing Storage Pak. The exhaust fan was activated by a temperature sensor set at 38oC inside the Storage Pak.

• we traveled in bulldust and kept checking for dust. We made some modifications around the filter and forced fan unit.
• we changed the filter shape and layers of material to test various combinations.
• We fitted a temperature datalogger in the Storage pak with 3minute temperature readings for the entire trip

The result is a redesign of the Filtration system and have both the inlet and outlet filtered vents in a different position and to make the filter system more easily accessible for maintenance. The 2004 Model will use a corrugated design industrial air filter approx 100mm x 100mm on both the air inlet and outlet. The unique design is based on a change in air velocity as it moves through 2 layers of filter, with the fine dust “falling out” between the 2 layers. Consequently, maintenance is key with approx a tablespoon of dust being removed after 2-3 days from the filter.

To test the electrical energy system with various power sources and batteries:

• we started with Gell cells for the first part of the trip, then switched to AGM's (absorbed Glass Mat), then switched to Flooded acid.
• We ran each set down to the lowest voltage before the freezer would cut out (generally around 10.7V) and then we charged the batteries from various sources and monitored the charging efficiency. We monitored the battery voltage, the current flows and the total Amphours used and/or provided through charging.
• We used both types of solar technologies in parallel charging 2 different Campers and did not use the generators whilst in the national parks
• We had high loads for special flash lighting for photographs that required 3000 Watts which was provided by both Honda Generators

The end result is best shown from the datalogger inside the freezer (right on bottom) which is shown below. You can read on the time scale the starting date of September 27th and the end date of October 8th . The freezer remained between - 2oc and - 8oc for the entire trip. This is an 80 Liter Autofridge located inside the new Gullwing Storage pak.