A Retrospective Rebuild

Recently, the leisure battery system in Wanderbus failed unexpectedly. While it wasn’t something we ever planned for, it gave us the opportunity to step back and completely rethink how our electrical system should work — not just for performance, but for safety, serviceability, and long-term reliability.

This rebuild wasn’t about adding more power (although with LifePo4 we technically have way more). It was about building a system that is easier to inspect, easier to maintain, and easier to deal with if something ever goes wrong again.

Here’s what we changed — and why.

The Goals for the New System

Before buying a single component, we set a few clear rules for the rebuild:

Each battery must be individually protected
Batteries must be removable quickly without dismantling the van
Key components should not sit on the battery lid
The system should be visually inspectable at any time
Monitoring needed to improve significantly
Fire mitigation should be built into the design

Designing around failure rather than perfection completely changed how we approached the installation.

Why We Chose Roamer Smart 5 Batteries

After speaking with several manufacturers and reviewing different options, we chose Roamer Smart 5 LiFePO₄ batteries.

The decision came down to a few practical factors:

Integrated monitoring that works seamlessly with our Victron system
Physical size and weight suitable for a retrofit install
Confidence in handling and removing the batteries if required
Strong warranty and cycle life expectations
A company approach that aligned with how we wanted to build the system

We installed two 340Ah Smart 5 batteries, giving us a large usable capacity while still allowing each battery to be handled individually if needed.

5% Discount on Roamer Batteries

After working closely with Roamer during this rebuild, we became ambassadors for their products.

If you’re considering a similar upgrade, you can use the link and code below:

👉 https://roamer.com/wanderbus
👉 Use code: WANDER5 for 5% off your order

The partnership came after the design decisions — but it means we can pass on a small saving to others planning their own installs.

Moving the Electrical Layout (A Big Lesson Learned)

Previously, parts of our power distribution system sat on top of the battery enclosure. That made maintenance difficult and slowed access when we needed it most.

In the rebuild we:

Relocated the Victron Lynx distribution system to the rear wall
Installed an uprated battery switch connected directly to the busbar
Ran equal-length cables from each battery
Reduced connection points to minimise resistance and complexity

The result is a cleaner installation that can be isolated quickly and worked on safely.

Individual Battery Protection

One of the biggest changes was how the batteries are protected.

Each battery now has its own terminal-mounted fuse, meaning:

A fault in one battery can be isolated immediately
The remaining battery can continue powering the system
Protection starts directly at the energy source

This was a non-negotiable improvement after the previous setup.

A Custom Battery Enclosure

Because this is a retrofit build, we designed a completely new enclosure using 2020 aluminium extrusion.

The new enclosure includes:

A rigid but lightweight battery cradle
A clear inspection door for visual checks
Easy access for removal and maintenance
Secure restraint using nylon straps
Integrated LED lighting for visibility

The aim was simple: no hidden surprises and no dismantling panels just to check the system.

Fire Mitigation and Monitoring

Safety improvements were a major focus.

We added:

Ferro fire suppression stickers inside the enclosure, which automatically activate at high temperatures
A RuuviTag sensor to monitor enclosure temperature and humidity independently of the battery BMS
Improved ventilation through the floor

These additions provide early warning and passive protection without adding complexity.

Charging and System Upgrades

During the rebuild we also upgraded supporting components, including:

Larger inverter cabling to reduce voltage drop
A Victron Orion XS 1400 DC-DC charger. Thanks to Chris @bspksolar for this and for supplying fuses, cable, trunking and all the other Victron gear.
Improved cable routing and management throughout

Rather than chasing maximum performance, the goal was stable, predictable charging behaviour across all sources.

Designing for Real Van Life

This rebuild reinforced something important: real van life systems shouldn’t just work when everything is perfect — they should be manageable when things aren’t.

The new Wanderbus power system is:

Safer
Easier to service
Easier to monitor
Built with future maintenance in mind

And most importantly, it gives us confidence heading back out on the road.

Thinking About Upgrading Your Own System?

If you’re planning a LiFePO₄ upgrade or redesigning your electrical setup, take time to think about access and protection — not just capacity.

And if you’re looking at Roamer batteries, you can use:

👉 https://roamer.com/wanderbus
👉 Discount code: WANDER5 (5% off your order)

Watch The Vlog

You can watch the whole install here: https://youtu.be/b6um79WTQx8