Integration & Field Setup

Research date: 2026-09-24. Vehicle: Ford E350 shuttle-bus conversion. Context: Burning Man/BRC, Saguaro Man, regional burns, RTR, festivals, and remote trips. Playa = alkaline dust, wind, 90-100°F days, and cold nights. Vehicle power specs and budgets are maintained in Power & Solar.

Gear: (1) fat-tire e-trike 48V/52V, (2) drone w/ LiPo smart packs (USB-C), (3) RC car w/ LiPo balance charger, (4) LED kite (small/no battery), (5) ~24” low-power TV.

Gear-Specific Power Interfaces

The vehicle-level power design is maintained in Power & Solar: bank capacity, inverter settings and idle draw, solar sizing, generator operation, and the daily energy budget. This page records only the gear-specific charging paths and safety constraints.

Gear	Charging path	Constraint
E-trike	Stock charger from the inverter	Do not connect the trike battery directly to the 48V bank or a DC-DC converter.
Drone	Manufacturer-approved DC car charger from a fused 12V rail, if supported	Verify the charger’s input range and battery-hub requirements.
RC car	Balance charger from a fused 12V rail, if supported	Verify its DC input rating; charge at or below the pack/charger limits.
LED kite	USB power or its supplied charger	Prefer replaceable/rechargeable lighting rather than a sealed battery.
TV	Native-DC model from a fused 12V rail	Verify the TV input range and rail capacity before wiring.

The ordered Victron Orion-Tr Smart 48/12V 20A is a converter, not a battery charger. Size, fuse, and commission the DC rail as part of the vehicle electrical install; do not treat these gear notes as a substitute for that system design.

Item 1: E-trike (48V/52V pack, 80-150 lb, AC charger)

Path: stock AC charger → inverter → e-trike battery. Do NOT DIY-boost from the 48V bus.

Voltage compatibility: a 48V pack charges to 54.6V; 52V pack charges to 58.8V. A 48V-58.8V boost window is exactly where the DIY market is weakest and the fire risk is highest. Verified pitfalls:

Many e-bike/e-trike packs use BMS communication pins — the charger must handshake before charging (documented for Specialized/Bosch-class packs). A generic boost converter cannot. (Escape Forum, eMTB threads — MEDIUM/HIGH)
Direct-attach boost converters to Lithium packs with no charge algorithm = you are the charge controller. Endless Sphere + EBIKE Delight both: “anything not listed as a charger means YOU determine the stop-charge point… worst case a bad fire”. DIY court is a fire risk aboard a wood-and-foam bus. Skip it.
Purpose-built 48V-bank-input e-trike chargers: essentially nonexistent in 2026 (Victron Orion line is 12/24V outputs; Orion-TR 48/48-6 is a converter, not a charger). LOW confidence any off-the-shelf unit exists per trike brand — verify against your trike’s manual, but plan on inverter charging.

Check the selected trike’s battery label and stock charger’s input rating when calculating its energy use; record measured consumption in Power & Solar. Do not add a generic boost converter between the house bank and the trike battery.

Item 2: Drone (LiPo smart packs, USB-C PD)

Path: DJI 65W car charger on the 12V rail → USB-C PD → battery hub.

DJI 65W wall charger: 100-240V AC input, USB-C 65W (PPS/PD). DJI also sells a 65W car charger: 12.7-16V DC input, 65W out — runs directly off the Orion rail. Official DJI spec: https://store.dji.com/product/dji-65w-portable-charger and fern.tech DJI 65W car charger spec. HIGH confidence.
The hub (e.g., DJI Neo/Mavic-class two-way hubs) handles BMS comms + sequencing (charges batteries one/two/three at a time depending on charger wattage; ≥45W charges 3 sequentially). HIGH (DJI manual).
USB-C negotiation + PPS means the brick is a smart supply and will not overdrive the pack (mavicpilots verified). HIGH.

Item 3: RC car (LiPo packs, balance charger)

Path: hobby balance charger (native 12V input) on the Orion rail.

RC balance chargers (SkyRC, ISDT, HOTA class) take 12V DC input natively and contain the full charge algorithm + balance function + LiPo mode. This is exactly the “device with its own charge control” the Orion rail is safe for. HIGH confidence this class of charger works on 12V rail; MEDIUM on your specific model’s input spec — check label before wiring.
LiPo packs (RC): high-C pouch cells — the highest fire-risk item in this whole list (thin foil pouch, burst-power design; DroneTrader LiPo guide 2026). See safety section.
Follow the pack and charger manufacturer’s current limits. Record actual charge energy in the vehicle power log.

Item 4: LED kite (small pack or none)

Path: USB charging, whatever’s easiest. This item is a rounding error.

LED kites run on internal USB-charged LiPo or reel-mounted lights. Draw at the pack level: ~0.5-2W running. Charge from any USB-A/USB-C port (12V-rail USB converter or phone charger).
The kite model and battery are not selected yet; choose one with a replaceable USB-charged light or use a small USB power bank.

Item 5: ~24” low-power smart TV (<30W, native DC target)

Path: native 12V/24V DC TV on the Orion rail. Do NOT run this through the 5kW inverter.

Verified 24” native-12V options (2026, all <32W, wide-voltage input 9-32V):
- Sylvox 24” Limo QLED: <32W, DC 9-32V + AC 100-240V dual input, Google TV, ~3.6 kg (https://sylvoxtv.ca/products/24-smart-12v-rv-tv-2026-limo-qled-series-with-dvd-combo)
- Majestic GTV2400DA 24”: 1.8A @ 12V = 21.6W, 9.5-30V DC input (https://crdoceania.com.au/crdrv/majestic-24-12-volt-smart-led-tv-…)
- Englaon LED24M80: 30W @ 12V, 10-30V surge protection, 2.7 kg
- Independent measurement (YouTube, Gear & Gadget, Sept 2025): Sylvox 24” streaming = 20-21W on 12V; same TV via inverter = 35W (inverter overhead ~15W). HIGH confidence on 20-32W range; MEDIUM on your specific set.
Wide-input (9-32V) matters, even on a regulated rail: forum-documented backlight deaths from TVs wired to a charging bus at 14.4V+. The Orion rail holds 12.2V regulated so this specific risk is mitigated — but wide-input sets also tolerate Orion output sag during rail-peak (e.g., while LiPo charging). Buy wide-input. HIGH.
Surge: LED TV inrush at power-on ~2× for a second; trivial.
Streaming stick (Roku/Fire ~2-4W on USB power) if the 12V set is non-smart — don’t pay the “smart” markup if the set is dumb; a 12V panel + $30 stick + Starlink/cellular hotspot is the standard RV play (iRV2, Forest River forums consensus).

Charging sequence

Charge lithium packs only with their matching manufacturer chargers and within their temperature and current limits.
Supervise every lithium charge; never charge unattended or overnight.
Keep charging within the installed circuit and inverter ratings. Coordinate timing with solar or generator operation using the vehicle power plan.

Use the Power & Solar page for system sizing and combine its base-load figures with measured gear charging energy before changing the array or battery plan. Record actual gear loads during the first trips rather than treating early pack-size estimates as fixed design values.

Storage & Physical Integration

E-trike + generator: pull-behind trailer (RECOMMENDED) vs hitch rack

2026-09 revision — an owned WEN DF1100T (214 lb, 11 kW dual-fuel) joined the stack. That weight + fuel fumes change the storage decision: the trike + generator + fuel should NOT ride on/inside the bus. Recommended path is a pull-behind trailer; the hitch rack remains the fallback for trike-only trips.

Trailer (recommended — enclosed 5×8 single axle, used $1,500–3,000):

Carries trike (80–150 lb) + DF1100T (214 lb + ~40 lb fuel) + spares/ramps/gear in one place, all weight off the bus except tongue. Solves the unverified-payload problem for the two heaviest gear items.
Enclosed = dust shield + rain + lockable storage (trike covered, per the dust + theft playbook below).
Generator runs OUTSIDE the trailer, always — no CO sensor, never run inside an enclosed box (CO + fire + fumes). Store with gas drained/stabilized, vents cracked.
Weight math: ~1,600 lb gross loaded (1,200 empty + ~250 trike + ~250 gen/fuel + spares) · tongue ~10–15% = 160–255 lb on the receiver — needs a Class III/IV receiver rated ≥ the tongue. [VERIFY] hitch class/rating stamp; receiver existence CONFIRMED by owner (2026-09). Tow rating on 5.4L E350 cutaway ~7,000–7,400 lb (Ford towing guides; VIN-derated configs possible) — trailer is 1/4 of that. [VERIFY] door-jamb GCWR/tow rating + 7-pin/brake wiring availability.
Trailer spin-ups: hitch/coupler/wheel locks + AirTag (security), registration/insurance, home storage when not traveling, ~1–2 mpg hit, narrow event lanes + backing in crowds.
Trailer tires on playa: hard-packed fine, soft shoulders sink — keep in bus tracks.

Hitch rack (fallback for trike-only, no gen):

200–220 lb platform class with ramps (Rack N Ride eTrike 220 lb, OutfitR/Emojo 200 lb, HitchRackPro 250 lb) on a 2” Class III/IV receiver; rack self-weight 32–95 lb; trike + rack ~115–245 lb cantilevered — anti-tilt bracket + 2nd hitch bolt mandatory (documented vibration failure mode).
Do NOT carry the trike OR generator inside the bus: grease/dust/moving mass + 214 lb of fuel fumes in the living space is dirty, an 80/20 fire/unsecured-mass hazard in a crash, and eats floor you don’t have.

Both cases: remove the trike battery when transporting/at camp (temp + security, below). Generator + fuel cans NEVER in the bus.

TV: wall mount

VESA 100×100 on a swing-arm or zero-clearance mount, mounting wall must be reinforced (bus wall = sheet + foam insulation; back with plywood/aluminum plate). TV 2.7-3.6 kg — trivial.
Route 12V rail power to a fused outlet at the mount. Vibration-rated mount + 4G-vibration- tested TV (Sylvox class) — TV failures from road vibration are documented in RV forums.

Gear bins & charge station

Drone + RC + chargers + LiPo packs live in sealed dust-proof bins (Pelican/IK/hard plastic with gasket). Playa dust is alkaline and abrasive; it kills fans, connectors, and LiPo cells. HIGH.
Dedicated charge station: a 30×20” aluminum tray or steel ammo can on a non-flammable surface (metal table or directly on the tray). All packs charge inside rated LiPo bags (300-600°C+ containment). The station is the ONLY place charging happens. HIGH (safety sources below).
LED kite + spares: one small bin, USB bank.
E-trike: 1-2 saddle bags for lock, charger (kept in bus), spare tube, battery key.

Weight vs E350 payload

Ford E350 cutaway GVWR range 10,050-12,500 lb; E-450 w/ 6.8L up to 14,500 lb. Max payload (chassis, no body) 7,210-7,376 lb; E-450 8,730-9,040 lb (Ford E-Series spec sheets, 2014-2024). A shuttle-bus body eats 3,000-5,000 lb of that; real remaining payload is likely ~4,000-6,000 lb — but vehicular/weight-capacity.md is EMPTY (GVWR, curb weight, payload all TBD).
New gear adds: trike 80-150 + rack 32-95 + TV/mount ~8 + bins/packs ~60 + misc 50 ≈ ~230-360 lb total (hitch-rack case). Trailer case (2026-09): the trike + DF1100T generator move OFF the bus onto a trailer — bus adds only tongue ~160-255 lb + trailer hitch mass, and the ~230-360 lb in-payload load shrinks to ~60-160 lb (TV/mount + bins + misc). Against a 4,000-6,000 lb remaining payload this is ~2-4% — no problem. However:
- Action: read the door-jamb sticker (GVWR/GAWR) and hit a CAT scale — the bus may already be near limits with water/tools/passenger gear. MEDIUM-HIGH urgency, cheap.
- Watch rear GAWR: trike on hitch = all weight on the rear axle. Trailer case: only tongue (~160-255 lb) hits the receiver — rear GAWR impact shrinks; still re-weigh with the trailer loaded when doing Phase 0.

Security

Theft profile: e-trike w/ battery $1,500-3,500; DF1100T gen ~$900-1,100; trailer $1,500-3,000; drone $500-1,500 + packs; RC $200-600 + packs; TV $250-400. Playa = open camp culture, but theft at regional burns and BRC has been real since ~2019 and rises with event size. Assume anything visible+unlocked is a target.

E-trike (highest-value, most exposed — lives on the trailer or hitch rack)

Remove the battery every night — it’s 40% of the trike’s value, locks into the frame in 10 seconds, and gets temp-controlled inside (wins for both security AND battery health).
Receiver lock (locking hitch pin) on the rack + anti-tilt bracket.
Chain the frame + BOTH rear wheels to the bus chassis w/ a 12mm+ hardened chain and disc-lock, or a kryptonite-style U-lock through frame + receiver. (sunlightandpower.com playa build: cable bike lock through a transom gasket on the power box — same trick works for the trike.)
Cover the trike when parked at the event (deters casual lift, sheds dust).
AirTag/other tracker in the frame tube. $25 insurance.
At festivals: park the trike so someone must step into the camp to reach it, not adjacent to the public walkway.

Trailer + generator (2026-09 addition)

Hitch/coupler lock + wheel lock + receiver lock — a chained coupler is the #1 trailer-theft defense; the wheel lock defeats dolly theft. AirTag hidden in the trailer frame + inside the gen.
Generator chained inside the trailer at camp and to the trailer frame — a 214 lb gen rolls on wheels, lifts by 2. Chain + disc-lock.
Do NOT chock the trailer with the coupler lock only — also chock a wheel at camp (anti-roll + theft).
Trailer parked at festivals so the rear door faces camp, not the public walkway; doors locked at night.
Gen exhaust/CO: gen runs 20 ft+ downwind of bus + trailer, on the ground, never in the trailer.
Fuel cans secured + ground-strapped when hauling; never inside the bus; never in the trailer with a running gen.

Gear bins & TV

Gear bin = a lockable steel/toolbox-style bin in the bus, or the dust bin + a cable lock threaded through the lid handles into the bus frame. Never leave drone/RC visible through windows. HIGH.
TV discreet — it mounts inside the bus; fine. If you ever set up a camp kitchen/table outside, don’t place the TV where it’s visible from the road.
Drone at the event: tether to a table corner when idle (playa wind + curious kids = drone gone in a gust).
Check event/camp norms: people do leave gear out for days at BRC in gated-area camps; your non-gated camp does not get to do that.

Travel days

Gear is most vulnerable at gas stations/food stops. All bins + TV inside, trike chained even for a 10-min stop.
When sleeping at truck stops: e-trike battery inside, trike chained.

Event-Day Logistics

Dust-proofing (playa: alkaline, wind-driven, gets everywhere)

Positive pressure is the highest-leverage playa trick: a 6” grow fan at a window pushing HEPA/truck-filtered air in keeps dust out without taping 20 windows (r/BurningMan, documented school-bus practice every year). Seal obvious gaps (hatches, vents) as backup.
Gear strategy: sealed bins + charge-port dust caps on the trike battery (rubber plug / XT60-covers); never charge with open charge ports in wind. HIGH.
Orion converter + charger station live in the dust-controlled interior or a vented box; the documented playa power-box build = 57-gal tub, MERV-8 filter intake + USB exhaust fan, transom-gasket cord pass-through (sunlightandpower.com, 2024). Copy it for anything that must run outside.
Follow the install and panel-maintenance guidance in Power & Solar. After a dust storm, inspect the array before relying on expected solar production.
Shade structure over/next to the bus drops interior ambient 10-15°F — matters for batteries (below) and comfort.

Charging at the event (the lithium safety section)

Non-negotiable rules, from EV Fire Solutions (2026), NFPA, NSW Fair Trading, Giant/JBI e-bike safety manuals — all say the same thing (HIGH confidence, cited):

Never charge lithium unattended, ever. Never overnight while asleep. Unattended overnight charging is the #1 cause of catastrophic lithium pack fires in RVs and e-mobility (EV Fire Solutions 2026 RV/e-scooter/e-bike fire review; NFPA 1192 2026 lithium task-group findings). In an enclosed RV the vent-gas from a runaway cell can reach ignition threshold before the pack BMS trips (NFPA 1192 Lithium task-group analysis 2026). Unattended = asleep, in the shower, at a gas station bathroom, away from camp — all of it. Unattended = the fire that grows while you’re not there. This is why the whole section below says “one adult awake and within earshot” — not “within sight”, not “nearby”. [VERIFY] EV Fire Solutions 2026 RV-e-mobility fire review + NFPA 1192 2026 lithium task-group if you want the actual incident numbers. overnight charging = “the single highest-risk behaviour in RV travel today” (EV Fire Solutions 2026). In an enclosed RV the vent-gas from a runaway cell can reach ignition threshold before the pack BMS trips (NFPA 1192 Lithium task-group analysis 2026).
Charge only on hard non-flammable surfaces (metal tray/ammo can + LiPo bag), in a ventilated area, out of sun, away from the exit path.
Charge during daylight, one adult awake and within earshot. Unplug at full.
Cool packs before charging — never charge a pack hot from riding/flying (let it sit 30-60 min). HIGH.
Use only manufacturer/stock chargers connected directly — no extension cords, no “compatible” knockoffs (recurring factor in e-bike fires; NYC data via CalBike). HIGH.
Standard dry-powder extinguisher will NOT stop LiPo/e-bike thermal runaway — carry a lithium-rated extinguisher + EV fire blanket; if a pack vents: evacuate everyone, get 30m upwind (toxic HF gas), call 911, do not re-enter. HIGH.

Battery temps in desert heat

Enclosed bus in playa sun = 60-65°C+ interior (EV Fire Solutions). Portable lithium pack charging limits are typically 0-45°C; follow the selected pack manufacturer’s specifications.
Portable packs (trike/drone/RC/LED) ride INSIDE but not sealed in a hot oven: shade the bus, crack a vent, or store packs in the 57-gal vented tub with fan. Never leave packs in a closed car/bus mid-day. HIGH.
Charge times: avoid the hottest part of the day; charge only when the pack is within its manufacturer’s temperature limits and the charging area is attended.
Storage between events: packs at 40-60% SoC, cool dry place (storage best practice, multiple manufacturer + fire-safety sources; HIGH). Full packs stored in summer heat age fast and swell.
LiPo telltales — swollen, leaking, hot, smelly pack: stop charging, isolate outside in a metal can, retire it (DJI + DroneTrader + Giant manual; HIGH).

Standard checks: UL certification

Buy with UL standards where possible — e-trike battery/charger: UL 2849 (whole e-bike) or UL 2271 (LEV battery); e-scooter/hoverboard class: UL 2272; charger + battery pairs must match. Certified gear + supervised daylight charging nearly eliminates the fire risk (njbikeped 2024, CalBike 2023; HIGH).

Confidence Summary

Recommendation	Confidence	Verify before buying
Fused 12V rail for compatible DC chargers and TV	HIGH concept	Confirm installed converter model, rail amp budget, branch fusing, and device input ratings
E-trike charges via stock AC charger + inverter	HIGH (no verified 48V-input DC trike charger exists; DIY boost = fire risk)	Check trike manual for BMS comm; confirm pack Wh from label
E-trike battery NOT charged from the Orion (it’s a converter, not a charger)	HIGH	—
Drone: vehicle-rated car charger where compatible	HIGH	Confirm the model’s charger and battery-hub specifications
RC: hobby balance charger on rail, ≤1C, LiPo bag	HIGH for rail compatibility; MEDIUM for your charger’s input spec	Label the charger input (12V DC?)
TV: native DC model with wide input	HIGH (vendor specifications)	Confirm the model’s voltage range, power draw, VESA pattern, and mount backing
E-trike on 200-220 lb class hitch rack, battery removed nightly	HIGH for rack class; MEDIUM for exact trike fit	Measure wheelbase/track/tire width; verify receiver class
Enclosed 5×8 trailer for trike + DF1100T generator (2026-09)	HIGH for concept; MEDIUM for exact trailer/hitch fit	Hitch class/rating stamp; tongue 160-255 lb; 7-pin/wiring; VIN tow rating
Gen is bank-charger via ECO-WORTHY charger, never direct to electronics	HIGH (THD <15% verified)	Confirm ECO-WORTHY charger input accepts non-inverter gen
Payload fine at ~230-360 lb added (rack) / ~60-160 lb (trailer case)	MEDIUM — payload files are EMPTY	Door-jamb sticker + CAT scale weigh, with trike/trailer loaded
Never charge lithium unattended/indoors overnight	HIGH (EV Fire Solutions, NFPA, NSW, Giant/JBI, CalBike)	Buy LiPo bags, ammo can tray, lithium-rated extinguisher, smoke alarm
Playa: sealed bins and positive-pressure filtered air	HIGH (multiple burn-season field reports)	Build/kit the vented tub before the first burn
Packs stored at 40-60% SoC, shaded, ventilated	HIGH (manufacturer + fire-safety consensus)	—

Unknowns to close (each is one measurement): trike pack Wh + charger input W; TV watts; drone hub wattage class; RC pack capacity; bus payload (CAT scale). System-level power unknowns belong in Power & Solar.

Key sources

DJI 65W charger + DJI 65W car charger specs: store.dji.com / DJI PDF (verified 2026)
EV Fire Solutions “Caravan & RV Lithium Battery Fire Safety” 2026 (unattended charging = #1 risk; extinguisher/lithium-rated guidance)
NFPA 1192 2026 + RVIA Handbook (lithium task-group, enclosed-compartment runaway analysis); NFPA e-bike safety portal
NSW Fair Trading lithium-ion safety; UL 2849/2271/2272 via UL e-bike safety action center, njbikeped 2024, CalBike 2023
DroneTrader LiPo safety 2026; energyreservoir LiPo charging guidance (NFPA/CPSC citations)
JBI / Giant e-bike battery safety manuals (never charge unattended; charge on non-flammable surface; 0-45°C)
Ford E-Series cutaway spec sheets 2012-2024 (GVWR 10,050-14,500; payload 7,210-9,040)
eTrike hitch rack class (Rack N Ride 220 lb, OutfitR/Emojo 200 lb, HitchRackPro 250 lb; Addmotor trike weights — 86-198 lb)
Sylvox/Majestic/Englaon 24” 12V TV specs + independent 20-21W measurement (Sept 2025)
r/BurningMan positive-pressure dust defense
ebikedelight.com, endless-sphere, diysolarforum — e-bike DC charging reality + DIY boost converter fire-risk consensus