Utopia Camper II - Bucher Mowag Duro

Finally, after years of research for the ideal compromised truck size with independent suspension, I found the Bucher Mowag Duro... only 64 in private hands!

TOTAL BUDGET = N$ 1,167,600 | WEIGHT = Kg 7,113

See our idea in 3D | hide content

Truck | Vision

  • Duro_Animation.mp4

Vision

Play the video below to get the idea of the different layers of the build... or play with the 3D Model at the bottom of the page.

Truck | Base

  • IDpic.jpg

Model | budget = N$ 170,000 (incl travel, ownership & 2023 license) | weight = Kg 3,800 (chassis cab - no fuel)

Bucher Mowag Duro I 2006 I 6x6

  • clearance 38 cm
  • wheel base 353+115 cm
  • front angle 45 degre
  • rear angle 36 degre

  • power 240 hp
  • torque 600 Nm
  • weight 4 T -> 8 T
  • speed 90 km/h
  • fuel consumption 20 l/100 km (5 km/l)

Truck | Engine

  • Cummins6BT.mp4

Engine | budget = N$ 69,000 (incl transport & import tax into Swazi) | weight = Kg 30 (extra)

Cummins 6BT 12 valves - inLine injection pump

  • Cummins engine 6BT - 12 valves - 24 v - low pressure turbo
  • from China delivered in Durban
  • Kyle - Cummins Powered SA @ R45K
  • transport Durban - Pretoria @ 4K
  • transport Pretoria - Matsapha Swazi @ R5K
  • import tax Swazi on R20K + admin @ R5K
  • Peter's labour @ R10K
  • Fana's labour (part of conversion below)

I bought the above engine from Kyle (Cummins Powered SA).  It will arrive in Durban around mid June.  Then it will be sentto Pretoria where Fana (Impossible Engineering) will overall whatever needs to be fixed but surely the injection system, the water pump, replace the starter motor and fit a brand new low pressure turbo...  then send it to Swziland where Peter will fit it in the truck & test it.  He will also services what needs to be done. If everything is OK, someone will drive the truck through the border to Pretoria.  Fana will finish the conversion with the refurbished manual Fuller gearbox, a new low pressure turbo, aircon... 

Gearbox | budget = N$ 30,000 | weight = Kg 20 (extra)

  • manual 5 speed with overdrive
  • Fana has a gear box
  • gear level can not be in the passage - how to connect to gearbox?

Transport | budget = N$ 8,000 (Swazi-Pretoria)

  • the truck will need to be driven from Swazi to Pretoria - ask Leon or Sam

Conversion | budget = N$ 100,000 | weight = Kg 30 (aircon)

  • Peter to fit engine in Swazi
  • Fana to recondition what is necessary, put new gearbox & finish the conversion
  • add aircon

Truck | Suspension

Coils | weight = Kg 30 (extra)

  • independent suspension - coils to be upgraded to 8-9 T

Shocks | budget = N$ 35,000 (coils & shocks) | weight = Kg 30 (extra)

  • check Darrel of Mikem Suspension (Bilstein SA agent) +27 82 656 4473
  • new shocks & coils - Gary paid +/- R30K

Truck | Wheels

Rims (not now) (40 extra)

  • rim alu 30-40 kg
  • current rim 20" better to get 22.5" for more choices of tyres 295/80
  • Gary paid about R3K per rim starting from scratch
  • Neville Liebenberg +27 82 404 3216 - 82 921 6358 NJ Wheel & Steel Germiston SA
  • Jaco Pepler of Titan Wheels +27 82 563 4445 (Gary)

Tyres (not now) (80 extra)

  • new tyre cost about R5-6K (Gary) so better to get them in a country where they are cheap!
  • original size 275/80/20 but capable of 335 (wider better in sand but worst in rocks)
  • best size 295/80/225
  • road pressure 4-4.3 bar - dirt road 2-2.5 bar (speed must be lower!) - sand 1 bar even 0.5-0.6 bar in emergency // human feet pressure 0.4 bar
  • get 1 pair of tyre chains from military
  • no balancing necessary - rim are well balanced - good tyres too
  • about 40-48K for 8 new tyres

Spare Tyres | weight = Kg 160 (extra spare + frame)

  • 2 spare wheels at the back of the rear of the body
  • manual/hydraulic crane
  • frame tilting tyres down
  • get original rim from gary - ask Enya

Lifting System | budget = N$ 70,000 | weight = Kg 160

  • hydraulic 2-stage rams - 1 m extenstion
  • connect to power steering pumps
  • check Gert of Vaktin Hydraulics +27 82 556 8019
  • Gary paid +/- R70K
  • ask Norman

Tyre Monitor | budget = N$ 4,000

  • tyremoni 6 wheels @ Cymot - buy on sale!
  • 8-tyre monitor @ Masood

Truck | Components

  • 24vElectricWindowKit1.webloc
  • 2DoorsElectricWindowKit.webloc
  • 4DoorsCentralLocking.webloc
  • AirHorn1.webloc
  • AirHorn2.webloc
  • SAUsedTruckParts-Beqfin.webloc

Fuel Tanks | budget = N$ 15,000 | weight = Kg 440 (full)

  • fuel tank 400 l 20 l/km 2000 km autonomy in the middle
  • diesel
  • main tank feeds diesel heater
  • stainless steel 3cr12
  • ask Neurosta

Brakes (not now)

Air Filter | budget = N$ 1,000 | weight = Kg 4

  • Donaldson cyclone air filter for 5.9 l engine

Electrical | budget = N$ 2,000 | weight = Kg 2

  • air horn @ N$ 800
  • GPS tracker world coverage & no subscription @ N$ 500

Lights | budget = N$ 10,000 | weight = Kg 6

Truck | Driving Cabin

  • CarrWen_Cat-seat.pdf

Tilting | budget = N$ 4,000 | weight = Kg 10

  • how to keep tilting cabin with current design?
  • how to seal between driving cabin & box?

Insulation | budget = N$ 2,000 | weight = Kg 10

  • insulation & finishing

Seats | budget = N$ 10,000 | weight = Kg 20 (extra)

  • get nice seats from scrap yard
  • or buy new ones from China

Finishing | budget = N$ 2,000 | weight = Kg 20

  • finishing

Dashboard | budget = N$ 10,000 | weight = Kg 10

  • dashboard with switches & instruments
  • tablet for radio/music, navigation/gps & handfree bluetooth
  • tire monitor
  • 2-way radio

Electrical | budget = N$ 4,000 | weight = Kg 10

  • central lock
  • electric windows
  • lighting

Box | Subframe

Subframe | budget = N$ 10,000 | weight = Kg 140

  • very rid chassis because of independant suspension
  • 20x40x2 mm steel frame with 8 points to fix on chassis
  • 60 m @ 1.88 kg/m = 110 kg + 8 brackets

Box | Shell

Panels | budget = N$ 70,000 | weight = Kg 600

  • length 560 x width 210 x height 220 cm
  • keep front & rear min 35 degre angles
  • better buy local from Kevin of Styrotex
  • 50 mm chromadec/high density polystyrene +/- NAD 450-500/m2
  • glue silicone?
  • aluminium corners 75-150 outside - 25-40 inside + glue & rivets
  • 60 m2 panels @ 8 kg/m2

Box | Openings

  • SteveDing_Cat-window.pdf
  • SteveDing_CeilingVent.jpg
  • Tina_Cat-camper.pdf
  • VivianHu_Cat-window.pdf

Main Door | budget = N$ 4,000 | weight = Kg 20

  • doors must have locking system top & bottom to avoid banana shape when outside & inside temperature are very different
  • door entrance lower floor for shower & getting in
  • door in 2 panels
  • insect screed

Steps | budget = N$ 3,000 | weight = Kg 10

  • steps to door must be folding outside

Hatches | budget = N$ 8,000 | weight = Kg 20

  • seal 100 % water/dust proof
  • hinges, locks, seals...

Windows | budget = N$ 40,000 | weight = Kg 40

  • windows with double glass & dry air in between with drying material that can be replaced (no vaccuum)
  • integrated blind
  • screed for insects must be sealed on sides
  • must have hidden hinges
  • Aldo & Marco of AluFitt Aluminium Solution +27 83 251 7539 & +27 83 959 5697

Slide Out | budget = N$ 10,000 | weight = Kg 100

  • 4 heavy duty sliders + 2 linear actuators (deplacement 500-600 mm)
  • or buy kit?
  • rv have a canvas unrolling on top to limit rain

Plumbing | Storage

Water Tanks | budget = N$ 16,000 | weight = Kg 450 (full)

  • water tank 400 l in the middle
  • electric pump to fill in water from river / borehole with pre-filter + 30 m hose
  • grey water tank 100 l
  • recycled water tank for shower?
  • valve to empty grey water tank easily accessible
  • stainless steel 3cr12

Plumbing | Piping

  • WaterPump1.jpg
  • WaterPump2.jpg

Pumps | budget = N$ 6,000 | weight = Kg 10

  • booster pump

Pipes | budget = N$ 4,000 | weight = Kg 10

  • booster pump
  • pipes

Filtration | budget = N$ 3,000 | weight = Kg 5

  • 3 stages water filter & booster pump
  • small tap next to sink

Geyser | budget = N$ 10,000 | weight = Kg 40

  • heat water from engine
  • insulated tank at 90 degre keeps water hot for 3 days
  • article

Waste Water | budget = N$ 2,000 | weight = Kg 10

Plumbing | Climate

  • JuneWu_Heater.jpg
  • JuneWu_Heater.pdf

Cooling | budget = N$ 30,000 | weight = Kg 40

  • air conditioning seems to be necessary
  • no ac on roof - must be integrated
  • 24 v unit

Heater | budget = N$ 10,000 | weight = Kg 20

Plumbing | Sanitary

Kitchen | budget = N$ 4,000 | weight = Kg 10

  • double sink with wooden board to close one
  • mixer with spray hose
  • small tap for drinking water

Shower | budget = N$ 4,000 | weight = Kg 10

  • walking shower from entrance door to save space
  • DIY fiberglass basin lower than floor - covered with wooden floor
  • simple outside shower
  • min size 80 x 100 cm
  • recycling water?

Toilet | budget = N$ 4,000 | weight = Kg 10

  • research compost toilet
  • DIY compost toilet
  • get plastic pee separator
  • add fan to blow smell outside when the toilet is open
  • double storage : solid & liquid
  • bidet shower a must but no water inside toilet - only in pee side
  • add raw sugar or vinegar for pee smell
  • get rid of pee (good fertilizer for plants & trees)
  • add pine wood shavings in solid
  • ideally the toilet should slide out of a box, get on top of the containers stored under the truck (better ventilation, easier to empty)

Electrical | Power

  • AnnaYuanJie_Q-battery.jpg
  • AnnaYuanJie_Q-solarjpg.jpg
  • IrisHuang_C-batteries.pdf
  • IrisHuang_Q-solar.pdf
  • IrisHuang_SolarPanel.jpg
  • JasmineHuang_Battery.pdf
  • MiaZhang_Cat-batteries.pdf
  • MiaZhang_Cat-solar.pdf
  • MiaZhang_PL.xlsx
  • MiaZhang_Q-solar.xlsx
  • YvetteChen_Q-battery.xlsx

Solar Panels | budget = N$ 16,000 | weight = Kg 100

  • min 1600 W solar panels
  • protected from trees
  • some sliding (to use roof as deck) 

Inverter | budget = N$ 20,000 | weight = Kg 20

  • 5 KW true sine inverter
  • how much power to run induction, oven, heater, appliances...

Storage | budget = N$ 50,000 | weight = Kg 100

  • double charger 2x1 KW
  • lithium batteries 10 KW

Monitoring | budget = N$ 10,000 | weight = Kg 20

  • android control system
  • water tanks level
  • diesel tank level
  • power from generator/solar/load
  • light switches
  • security cameras

Electrical | Lighting

Inside | budget = N$ 6,000 | weight = Kg 10

  • led lights
  • controlled by wifi

Outside | budget = N$ 2,000 | weight = Kg 10

  • security lights outside
  • controlled by wifi

Electrical | Appliances

  • Devanti5KGMiniWashingMachine.webloc
  • Midea6PlaceDishwasher .webloc

Fridge-freezer | budget = N$ 5,000 | weight = Kg 30

  • big fridge / freezer (at bottom) 130-150 l
  • AAA+ electrical consumption
  • best size?

Stove | budget = N$ 7,000 | weight = Kg 20

  • 3-burners induction stove (i.e. Ecotouch)

Oven-microwave | budget = N$ 2,000 | weight = Kg 8

  • combined convection oven / microwave

Coffee Maker | budget = N$ 5,000 | weight = Kg 6

  • small coffee/espresso maker

Dish Washer | budget = N$ 4,000 | weight = Kg 14

  • more economical to have small dish washer (uses only 4-6 l)
  • more hygienic against tropical diseases
  • Midea 6-place countertop dish washer uses 6.5-8 l only - A+ (WxDxH) 550 x 500 x 438 mm

Washing Machine | budget = N$ 5,000 | weight = Kg 16

  • 3-4kg washing machine electrical or simple manual one (shaking when driving)
  • make sure it is blocked while driving!
  • special trap for dirty laundry

Vaccuum Cleaner | budget = N$ 1,500 | weight = Kg 5

  • vacuum cleaner - small model - wireless

Electrical | IT

Satellite | budget = N$ 11,000 (+ 2500/mo) | weight = Kg 12

  • check StarLink mobile internet by SpaceX
  • Starlink RV internet costs $135 per month with an up-front $599 equipment fee

Cellular | budget = N$ 9,500 | weight = Kg 5

  • cellular booster antenna (i.e. Puck-5)
  • 12 v wifi router (i.e. Teltonika RUTX11 dual sim LTE router with auto fail over from sim1 to sim2 if connectivity drops

Monitor | budget = N$ 10,000 | weight = Kg 10

  • xtra monitor near table

Furniture | Bedroom

Bed | budget = N$ 8,000 | weight = Kg 50

  • queen bed 157 x 200 cm

Cuboards | budget = N$ 6,000 | weight = Kg 20

  • small material

Furniture | Dining

  • Table90-180DegreeLockingHinges.webloc
  • TableTelescopicLeg1.webloc
  • TableTelescopicLeg2.webloc

Table | budget = N$ 8,000 | weight = Kg 20

Seating | budget = N$ 14,000 | weight = Kg 40

  • seating for 4-6 people
  • collapsing to make a bed for 2 people
  • including storage & cushions

Furniture | Kitchen

Counter | budget = N$ 10,000 | weight = Kg 20

  • storage cupboards & drawers
  • sliding out to give more space inside

Workshop | Ebike

  • ElectricMotorbike8000wAlibaba.webloc
  • ElectricMotorcyclePhantom 6000WAliExpress.webloc
  • PeterZhu_Ebike1.png
  • PeterZhu_Ebike2.png

Electric Bike | budget = N$ 100,000 | weight = Kg 90

  • electric motorbike 50-100 km/h - 200 km autonomy - charging 6-8 h

Workshop | Recovery

  • LidaLi_Q-winch.pdf
  • RianWang_Q-winch.jpg
  • RianWang_Winch1.jpg
  • RianWang_Winch2.jpg
  • RianWang_Winch3.jpg

Winch | budget = N$ 50,000 | weight = Kg 80

  • 10T hydraulic winch with valves & remote controller

Recovery | budget = N$ 6,000 | weight = Kg 10

  • sand plates (DE army)
  • straps
  • jack

Workshop | Tools

Power Tools | budget = N$ 10,000 | weight = Kg 30

  • all power tools wireless with same battery
  • drill
  • jigsaw
  • blower
  • grinder

Tools | budget = N$ 4,000 | weight = Kg 30

  • ratchet box
  • spanners
  • screw drivers
  • hacksaw

3D Model | Sketchup

Sketchup 3D Model | budget = N$ 3,600 (sketchup 1800/y)