EP62: Rebuilding the Electrical System on Roam Begins

After more than a year of planning, staging parts, and waiting for the right moment, we finally begin building the core of Roam’s electrical system. This episode marks a major refit milestone — not just in design, but in real, physical progress.

In EP62, we move critical power equipment out of remote storage and into a dedicated utility space, then start mounting the heart of our 24V and 48v DC electrical system. It’s one of those projects where nothing is small, everything is heavy, and the layout decisions matter long before a single wire gets run.

Episode Summary

In EP62 of Sailing Roam, we begin building the core power infrastructure for our cruising catamaran. To reduce water intrusion risk and improve long-term serviceability, we relocate key electrical components from a deck locker into a newly created utility room in the forward captain’s berth.

To support the system, we fabricate a custom structural power wall using 1-inch Coosa board laminated with fiberglass and with aluminum bracing. As the layout takes shape, we discover that not everything fits as originally planned, forcing design changes before final installation. We bond the wall into place and begin mounting major Victron components, including inverters, chargers, DC bus bars, and AC panels.

This episode represents a turning point in the refit — moving from planning and prep into visible, permanent progress on the electrical system.

Why We Moved the Electrical System

The original plan placed major electrical equipment inside a deck locker — a location that posed an unacceptable risk for water intrusion and long-term reliability. Rather than build around that limitation, we decided to rethink the layout entirely.

By converting the forward captain’s berth and office into a dedicated utility room, we gain a safer, drier, and far more serviceable space for critical power equipment — a decision that will affect every system aboard Roam going forward.

Designing and Building the Power Wall

To support the electrical gear, we build a structural mounting wall using 1-inch Coosa board laminated with 1/4-inch fiberglass. Strength, rigidity, and long-term durability were the priorities here — this wall needs to hold heavy components and remain stable over time.

As we mocked up the layout, it became clear that some of the largest components, including the inverters, wouldn’t fit as originally planned. Rather than forcing the design, we adjusted the layout and relocated equipment to an adjacent wall before committing anything permanently.

Mounting the Core Victron Components

Once the wall was bonded in place using bolts and Sikaflex, we began mounting the core of the power system, including:

• Victron inverter and isolation transformer
• Two battery chargers
• DC/DC charger
• 24V and 48V DC bus bars
• AC electrical panels

This equipment had been staged and stored for nearly a year while other refit priorities took precedence, so finally seeing it mounted and taking shape felt like a major win.

A Visible Turning Point in the Refit

This episode isn’t about wiring or commissioning yet — that comes next. EP62 is about building the physical backbone that everything else will depend on.

After months of planning, design work, and waiting, progress is finally visible. The electrical system is no longer an idea on paper — it’s becoming a permanent part of the boat.

How This Fits Into the Bigger Electrical Rebuild

EP62 is the foundation for everything that follows in the electrical refit. Future episodes will cover wiring, system integration, commissioning, and real-world testing.

We’re documenting the full electrical rebuild — including schematics, decisions, and lessons learned — on a dedicated page here:

👉 Electrical Systems on Roam

What’s Next

With the core equipment mounted, the next phase will focus on wiring and that's going to take some time.

Thanks for following along. After a long stretch of prep, it feels good to finally see real progress.