Recreational Vans
A breaker panel is the traffic controller for both AC and DC power. It splits incoming energy into branch circuits, protects wiring from overloads, and gives you fast isolation when something goes wrong. Marine grade panels earn their reputation because they hold calibration across heat, cold, vibration, and spray. That reliability translates nicely to moving platforms like vans and expedition trucks where temperature and vibration are daily realities. The heart of the panel is the breaker itself which must trip before the wire insulation is stressed and must reset cleanly after the fault is cleared.
Adventure and marine systems commonly run a DC backbone at 12 or 24 volts with an inverter creating 120 volt AC for outlets and appliances. A DC breaker panel distributes loads like lights, fans, pumps, fridges, and charge sources while an AC panel handles outlets, induction cooktops, and shore power feeds. Keeping the AC and DC panels clearly separated but coherently labeled simplifies fault finding. Main disconnects on both sides act as the master off. If shore power is used, a main AC breaker and ground fault protection at the service entrance are essential.
Thermal breakers drift with temperature. Magnetic hydraulic breakers hold a predictable trip curve over a wide temperature range which is why they are favored for mobile and marine environments. They also offer trip free behavior which means the breaker will open under fault even if you hold the toggle on. That protects wiring and devices when heat and vibration would otherwise cause a nuisance or missed trip.
Breakers carry three vital specs. Continuous amperage tells you the steady load they can carry. Voltage rating must meet or exceed the system voltage. Interrupt rating indicates the maximum fault current they can safely clear. DC loads are often single pole while AC requires one or two poles depending on how the system is bonded. Choose trip values to protect the smallest wire downstream and map each circuit on a panel schedule for clarity.
Panel planning starts with a load list. Add up likely concurrent loads and peak draws then size the main breaker and wire to match. Leave headroom for future circuits because new gear always shows up. Busbars keep things tidy and safe by concentrating terminations and limiting stack height on breaker studs. A dedicated negative bus and a protected positive bus keep current paths short and logical. Use ring terminals, quality ferrules where appropriate, and avoid doubling lugs unless specified by the hardware.
Voltage drop matters for fridges, inverters, and fans that hate brownout. Keep branch circuit drop under three percent for critical loads and five percent for non critical. Select marine grade tinned copper cable, crimp with calibrated dies, and heat shrink all terminations. Chafe protection at every pass through extends service life on rough roads. Secure conductors every few inches and route away from sharp edges or heat.
A safe system gives every amp a clear return path during normal use and a controlled path during a fault. DC negative and chassis bonding must be intentional. For AC, the equipment grounding conductor should be continuous and the neutral to ground bond should live at only one defined location depending on shore power and inverter design. If shore power is used, add an inlet with a locking connector, a transfer scheme, and ground fault protection to meet safety expectations.
Use durable labels that can be read in low light. A panel schedule near eye level is worth its space when troubleshooting in the rain. Color code where it makes sense and match labels to wire markers. A system diagram tucked inside the panel door saves hours for any tech who touches the rig later.
Good installation is quiet installation. Breakers should not buzz, hot spots should not exist, and loads should start without dimming lights. Torque every terminal to spec and record those values for future checks. After commissioning, simulate a few faults on non critical circuits to confirm trip performance and polarity. Thermal imaging during full load helps spot loose connections before they become a problem.
Do not oversize breakers to stop nuisance trips. Fix the cause instead, usually wire size, loose terminations, or an overly long run. Do not mix aluminum and copper without proper interface materials. Do not place inverters or batteries in closed compartments without ventilation. Keep panels away from splash zones, fuel lines, or high heat sources, and maintain service loops so components can be removed without stressing conductors.
A multimeter, clamp meter, and a good sense of sequence are your best tools. Check voltage under load, confirm polarity, and verify that every breaker actually kills its labeled circuit. Keep a commissioning sheet with load currents, breaker ratings, and cable sizes. Recheck torque after a few heat cycles. Clean dust and inspect for corrosion at seasonal intervals.
If you add a high draw inverter, air conditioning, or fast charging, plan for a larger main breaker, heavier busbars, and additional distribution capacity. Growth is smoother when the original panel has spare spaces and the wire routes keep expansion in mind. Parallel DC panels or sub panels are common for separating house loads from charging and auxiliary circuits.
Once your system design is clear, professional integration delivers the quiet confidence you feel every time you press a switch. Our team uses marine grade distribution, magnetic hydraulic protection, and serviceable layouts that survive washboard roads and humid summers. We specify main protection, shore power entry, inverter transfer, and branch circuits with an eye on safety, future growth, and easy diagnostics. If you want a turn key adventure rig, start with our Recreational Vans lineup and we will match the right electrical backbone to your travel style.
When we design a custom van, electrical planning begins on day one and ends with a hands on walkthrough. You will see labeled panels, tidy harnesses, and a clean diagram for reference. Whether you need a compact weekend setup or a long range system for work and play, we can build it around reliable breaker panels and proven components, then test it under real loads before handoff.
Tell us what you want to run, how long you stay off grid, and where you travel. We will turn that into a right sized electrical system with marine grade protection, clean routing, and room to grow. Your only job is to pick the next road and go.
Ready for safe, quiet power that just works The OZK Customs team designs and installs marine grade electrical systems using proven breaker panels and clean layouts. Tell us how you travel and we will spec, build, and test your system so you can roll out with confidence. Start your custom power plan now.
ADDRESS:
6159 E Huntsville Rd, Fayetteville, AR 72701
PHONE:
(479) 326-9200
EMAIL:
info@ozkvans.com