Hi E277,
Glad I didn't overwhelm or annoy
I understand wanting to keep it simple on an older van (although my buddy's that we did is a '97, but I still get what you mean).
If you changed to a larger wire running back from the separator to the house battery (did you?) that is good. The one on my buddy's (my former) (Indiana) '97 is something like #8 - WAY too small. Voltage drop city. Changing that to a larger cable (which you can then even fuse for safety if you want to) will help get more voltage back from the alternator. That said, the alternator is still not a smart charger. Still, why waste what you can get from it.
Do you tend to do weekend trips only? If so, consider this for minimal outlay and complication (I will ignore proper fusing and etc. for the time being, since you aren't looking at a system overhaul, and this would not be making anything worse).
1) New house battery, so you know where you stand. If keeping the SMB "venting system," and the battery is under the couch (mine was), consider AGM for fewer venting concerns. Of course this goes against "cheap." So maybe keep flooded cell batteries....
2) If you can swing it, a second house battery (I added this, under the couch). This will double your available power over a weekend.
3) Now just plan on putting the power back when you get home, via plugging in/charger. If you can, put in a smart charger (will be much kinder to batteries, plus charge up to 100% much better). If you are going to be plugged in for a period of time (days), then you don't need a large one (smaller one takes longer). Maybe say something like this, which is a smart charger, but smaller amperage (I have a larger version of same in my current rig):
http://www.amazon.com/ProMariner-63120- ... ic+charger
It may be cheaper elsewhere.
(Note that I am not a charger expert, as plugging in is not my usual way, but these are well-rated by folks I trust in the marine industry.)
AGM's CAN take charge really fast, so with a generator (or short plug in times) you can really make good use of a larger (60 amp say) charger (who wants to listen to generator drone on and on). But if you are plugging in at home, then I don't see any reason 20 amps can't work fine. The "smart" charging is really helpful for treating the batteries well, plus getting that last 15% in. Lead-acid atteries generally don't like being charged up to only, say, 85% over and over (lithium is different, but we're not going there now).
If you are going the "cheap and replace" route, plus with predicatably short outings, then maybe don't spend for a monitor (I can't believe I'm saying that, LOL), but instead do some manual calculations. Say like this:
One weekend:
1) Furnace fan, amps x hours used.
2) Lights, amps x hours used.
3) Refrigerator (maybe not possible - do you use a cooler?)
4) Laptop charging (a 12 volt charger is better than using inverter plus 110 charger), amps x hours used.
etc. etc.
If you can put in enough amp hours in the battery bank so that the figures all add up to less than, say 75% of your amp hours (normally I'd say 50%, but you are going for cheap/replace theory on batteries), then you can just go about your business and then plug in for the week to re-charge, then repeat the next weekend.
Here is a chart for Lifeline batteries, for example, comparing percent of discharge vs. cycle life. You can see that 75% discharged will still work, especially in an "I know I'm going to kill these and then replace" scenario.
Hmm, not sure I remember how to get an image from my album to a post? I put the chart image in my album at any rate.