What does it take to build a vehicle capable of surviving the Arctic?

When we set out to build our 1983 Mercedes Unimog expedition vehicle, we weren't designing another camper. We were creating a vehicle capable of living comfortably in one of the harshest environments on Earth.

Every decision was made with reliability, self-sufficiency and ease of maintenance in mind. From the heating system to the electrical installation, this build demonstrates how thoughtful engineering can transform an already capable vehicle into a true expedition machine.

Whether you're planning an Arctic adventure or simply want to extend your camping season, many of the principles behind this build can be applied to any campervan conversion.

The Brief

The goal was simple.

Create a vehicle that could remain completely off-grid for extended periods while operating reliably in temperatures well below freezing.

That meant designing systems that would continue performing where many standard campervan installations begin to struggle.

We needed:

• Reliable heating in sub-zero temperatures
• Continuous hot water
• Engine pre-heating
• High electrical capacity
• Redundant heating systems
• Minimal reliance on campsites or external power

Every component had to earn its place.

The Biggest Challenge: Extreme Cold

Most campervan heating systems are designed around UK or European winters.

The Arctic is a different story.

Temperatures regularly fall below -30°C, diesel begins to gel, batteries become less efficient, condensation increases dramatically and recovering from equipment failure isn't always straightforward.

This meant designing systems that weren't simply powerful enough—but reliable enough to cope with prolonged exposure to extreme conditions.

Why We Chose Multiple AUTOTERM Heating Systems

Heating is the heart of any expedition vehicle.

Rather than relying on one heater to do everything, we designed the Unimog around multiple independent heating systems, each performing a specific role.

Dual AUTOTERM Air Heaters

Two independently controlled AUTOTERM 2kW air heaters provide warm, dry air throughout the living area.

Running two heaters offers several advantages.

Firstly, it allows us to distribute heat more evenly throughout the pod.

Secondly, it provides redundancy.

If one heater ever required servicing, the second could continue heating the vehicle—something that's incredibly valuable when you're hundreds of miles from the nearest workshop.

AUTOTERM Flow 5D

Alongside the air heaters sits one of our favourite products—the AUTOTERM Flow 5D coolant heater.

This single unit performs several jobs.

It pre-heats the engine before cold starts.

It provides continuous hot water.

It supplies warm coolant to the blower matrix.

It even feeds a heated towel rail within the bathroom, creating a practical drying space for wet clothing after a day in the snow.

By combining these functions into one system, we reduced complexity while improving efficiency.

Small Design Choices That Make a Big Difference

One of our favourite details isn't immediately obvious.

The fuel tanks and fuel lines supplying the heaters are mounted inside the insulated pod rather than underneath the vehicle.

Only the heater exhaust exits through dedicated skin fittings.

Why?

Because diesel can begin to gel in extremely low temperatures.

Keeping the fuel system protected inside the warm living space dramatically reduces this risk while also protecting components from water, road salt and road debris.

It's a relatively simple decision that can make a huge difference when travelling in harsh winter environments.

Powering Life Off-Grid

Heating is only one part of the equation.

To remain truly self-sufficient, the Unimog needed an electrical system capable of supporting life away from campsites for extended periods.

The result is a substantial Victron Energy installation featuring approximately:

• 1,000Ah of lithium battery storage
• 2,200W of solar generation
• Intelligent battery monitoring
• Large inverter capacity
• Automatic cooling for electrical components

One feature visitors often notice is the side-mounted solar panels.

While unusual, they serve an important purpose.

During Arctic winters, the sun sits low on the horizon, making vertical panels surprisingly effective compared with conventional roof-mounted arrays.

It's another example of designing around the environment instead of following convention.

Comfort Was Just as Important

Expedition vehicles aren't simply built to survive—they're built to be lived in.

Inside the Unimog you'll find:

• Spacious lounge seating
• Electric drop-down bed
• Full kitchen
• Heated bathroom
• Clever storage solutions
• Fold-away shower system
• Double-glazed windows
• Excellent ventilation

The result is a comfortable home capable of supporting long-term travel in remote locations.

What Can Campervan Owners Learn From This Build?

Although most people won't be driving across the Arctic, the principles behind this build apply to every campervan conversion.

Think about how your heating system will be used.

Protect components wherever possible.

Plan your electrical system alongside your heating requirements.

Choose equipment designed for reliability.

Design with maintenance in mind.

These considerations will improve your camper whether you're heading to Scotland in winter or Norway above the Arctic Circle.

Why We Love Projects Like This

Projects like our Unimog allow us to push products and systems to their limits.

They help us understand how equipment performs in real-world conditions and allow us to bring that knowledge into every installation we complete.

Whether we're fitting an AUTOTERM heater into a weekend camper or designing a fully bespoke expedition vehicle, the goal remains the same:

Build systems that our customers can rely on wherever their adventures take them.