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It does not need to be an overflow tank. Before the OP starts rebuilding the system, adding pumps and heat exchangers, it is worth it to just remove the camper expansion tank and see if that fixes the problem. Again only close one valve to the truck side to allow the camper loop to expand into...

The idea behind using a composting toilet for an expedition vehicle is to remove the blackwater and have extended use from the toilet by separating the #1 from the #2. You will not be "composting" and that is what confuses most people. A composting toilet is just a urine separating dry toilet...

Composting toilet.

Sorry I read Cabin Blower as "cab" blower. I think the "T" should be before the cabin blower. Try removing the cabin overflow/expansion tank from the system, it is not needed. As long as you only close one valve to the engine loop when using the Webasto while parked coolant can expand into the...

300 Watt panels are not too large. We have two 315 watt panels that have seen 6 years and over 100 00km of on and off road abuse.

Where is the vehicle radiator in the diagram? Is it with the "truck"? or is it with the cabin blower? Take a look at our layout from Webasto. Basically two loops with the Webasto in the middle. With this setup the cabin hot air blower is not part of the cabin heat loop.

Looking at the diagram, with all valves open and the truck running it should be pushing hot coolant through the hot water heat exchanger. Separating the two loops with a heat exchanger is not necessary and adds complexity to the system since you need you need to add a circulation pump to the...

Looks like a gimmick to avoid using full chains, I don't see how they can perform like full chains off road in mud and snow.

Friends of ours got round White rim in their Mercedes 1017, but that was with a camper that collapsed down to cab height and there were still significant issues with height.

More a walk through than pass through. We drive with the door in the open position. If a drawer has been left open by mistake or the cat wants our attention I want to hear it. The noise level is not much different open or closed.

Have you calculated your power needs? Larger domestic panels will give more watts per dollar. Don't get sucked in to one companies marketing, look for the best price on the best components you can afford. Victron and Magnum are good choices. 6 volt golf cart batteries will give the most Amp...

Webasto make coolant heaters (Thermotop C for example). For hot water to will also need a hot water tank with a calorifier(heat exchanger) such as the Isotemp Spa.https://www.indelwebastomarine.com/us/products/isotemp-water-heaters/spa/

It is common practice to tie the vehicle and camper coolant loops together. There is no reason the camper cooling loop should be any more prone to failure than the vehicle system. Shut off valves between the two circuits should be installed and easily accessible.

I would strongly recommend you do not wax or otherwise lubricate wheel studs. Clean with a wire brush.

Oil spray is a generic term for rust protection sprays in Canada. They are usually a waxy oil that will creep and displace water. Krown is a common brand. https://www.krown.com/en/canada/

Oil spray.

Sure, hard is the wrong word, how about "affects". Which affects mileage more? a flat panel mounted on a brick shaped vehicle or the alternator drag on the engine? 6 of one half a dozen of the other. I want my solar panels available to charge at all times.

Cab access? For me no cab camper access is a deal breaker. Consider dropping at least two steps inside the box. This is enough to get in and out (with a little stretch) without deploying the steps. It also avoids the ridiculous long scissor steps that extend 5' out from the side of the truck.

Charging off your alternator is also hard on fuel mileage.

It makes it easier but it is hard on the door hinges.