Buildmytruck

First day out for our new build.

The Iveco is almost built. And we're documenting how we got there.
This isn't a live build series — it's a look back at a 2023 Iveco Daily 4WD expedition vehicle build, with one honest question running through it: if we did it again, what would we change?
The electrical system? Not much. That was designed properly from the start — Victron NG battery system, fault current analysis, real load calculations. The process worked.
The CAD and fabrication side in Fusion 360? That's a different story. There's a better way to approach a complex vehicle build in Fusion, and we'll show you what that looks like.
No drama. No manufactured tension. Just a real build, honestly documented — the decisions, the process, and the things worth doing differently.
What's coming:
📹 Full documentary series — the electrical system design from first principles through to a working 24V expedition rig
📐 The Fusion 360 build — how the vehicle was modelled, and how we'd approach it now
🔧 The physical build — fabrication, fit-out, and what it took to make it real
First video is up. More coming.
Build My Truck — Engineered Systems · Outback Exploration
https://youtu.be/8HUq2mJH8AU

The Iveco Daily 4WD build — from delivery day to an almost finished expedition vehicle.
Custom steel subframe, aluminium sides, CNC interior, 24V Victron Lithium system. Three years and a lot of Fusion 360. The full build series is coming.

www.youtube.com

Well into our new project with the Iveco Daily 4x4. After months of design with Fusion 360 CAD, the subframe and bins are complete. Now fitting out plumbing before installing the floor.

Need help with your van. We are available for consulting in all areas but electrical is our focus. We don't supply equipment but will advise.

2022 Sprinter for Sale
We're moving on to our next build project. This 2022 MWB V6 419 has been extensively fitted out for two-person off grid touring. Just over 10,000 kilometres in near new condition.

• Toyo 245/75R16 AT3 tires with upgraded rear suspension
• ARB bull bar with driving lights
• Rock sliders (more for entry comfort)
• Spare wheel carrier
• Rooftop air conditioning, Maxfan, Starlink antenna and 600-watts of solar
• Extensive Victron electrical system including 600-amphours Victron lithium battery, 3000VA inverter charger and 250-amp alternator charging.
• 12-volt / 240-volt electric hot water system
• Fully insulated interior
• Maxfan for ventilation. All windows have fly screens and privacy shades.
• Diesel heater
• Two single beds
• Extensive drawer storage
• Over two metres of benchtop
• Dedicated wet area for shower and toilet

Available for viewing at the Sunshine Coast. $180,000

PM to discuss.

How much can you fit on your Sprinter van MWB rooftop?
- 3 x 200-watt solar panels
- MaxFan
- Dometic Harrier Lite air conditioner
- Starlink Dish

It's always a daunting task to cut holes in a new van. Here is an installation process of Dometic SP7 windows in a Sprinter MWB 144 van.

How much weight on top of your van?
The Sprinter 4WD already has a high center of gravity so it's best to keep the weight down up top. Mercedes specifies 150 Kg for the maximum rooftop load. Our objective was to maximise the amount of solar, have rooftop air conditioning and a fan for ventilation along with minimal wind drag.

The solution was a custom solar panel mounting rack that bolts to the van roof rail mounting points. The following gear was added:

Solar Panels - 3 x 200-watt panels - 30 kg
Aircon - Dometic Harrier Light - 36 kg
Maxfan Deluxe - 7.6 kg
Total: 93 kg

Air conditioning with 600-watts of solar and a Maxfan is a good result. A bonus was a sail track on the left side for a slide in awning and Starlink antenna when parked..

But we also need to consider internal overhead storage and ceiling weights if we are trying to keep the "high" weight in the van to maximise stability.

To that end a lightweight plywood structure was used without doors. In practice we only store lighter clothes, gadgets, and toiletries up top.

Overhead Bin Storage - 19 kg

Finally, the weight of the internal ceiling should be considered. In our case, a set of roof gussets provide a flat and level surface for the roof panel, Maxfan and air conditioner mounting.

Roof Gussets - 10 kg
Ceiling Panel (5 mm plywood) - 10 kg

In summary, the equipment and furniture around the top of the van weighs in at 132 kg.