Truck Update 4/21/19

  • Started trip route planning
  • Replaced cabinet hinge pins with small stainless steel bolts and lock nuts
  • Added foam shock cushion to air heater fuel pump mount
  • Added footman’s loops and Velcro straps to secure kitchen cabinet doors
  • Modified/improved engine pre-heater switch mounting in truck cab
  • Turned off axle fording air supply (turned off air regulator)
  • Researched:
    • Other locking fuel tank cap options
    • Air heater ducting insulation
    • Speedometer upgrade options
    • Entry ladder modifications and storing options
    • Electric air compressor wiring modification
    • Engine pre-heater use procedure
  • Bonded and cut foam for Fantastic Vent plug
  • Fabricated pour spout for gallon alcohol cans (for stove fuel)
  • Organized spare parts, extra material, and provisioning
  • Researched electronic maps for route planning
  • Received 2019 Milepost Alaska trip planning book
  • Corresponded with electronic speedometer company
  • Ordered programmable electronic speedometer and sending unit
  • Filled, pressurized, and tested fresh water system
  • Filled and test drained gray water tank system
  • Rewired inside of ARB air compressor
  • Ordered and received material for new speedometer bezel
  • Ordered, received, and installed food grade rubber hose for faucet to sink
  • Received and installed new locking fuel cap
  • Purchase pneumatic components for air compressor installation
  • Purchased hose to drain gray water tank
  • Received heater duct insulation
  • Installed heater duct insulation
  • Fabricated rubber compressor mount pad
  • Installed electric air compressor
  • Plumbed air compressor into truck pneumatic system
  • Started routing air compressor wiring
  • Started laying out new folding ladder design
  • Ordered and received components for auxiliary air take-off system
  • Purchased wheels for new folding ladder base
  • Removed and cleaned section of forward gladhand stainless steel line from truck pneumatic system
  • Added regulated air take-off from high pressure side of truck pneumatic system
  • Removed old speedometer and speedometer calibration gearbox from transmission
  • Cleaned up speedometer calibration gearbox
  • Cut up (newly purchased) folding ladder to make parts for new folding habitat ladder
  • Machined new Delrin bezel for fitting new speedometer in old dash panel hole
  • Started bolting new habitat ladder together
  • Fabricated compression plugs for inside tubes of new ladder assembly
  • Finished wiring electric air compressor
  • Tested electric air compressor and filled truck tanks with engine turned off
  • Started fabricating ladder wheel mounts
  • Received new programmable electronic speedometer
  • Wired lights for new speedometer
  • Fabricated wiring harness for new speedometer
  • Fabricated steel upper mounting tabs for new ladder
  • Modified existing habitat ladder mount to accommodate old and new ladders
  • Re-installed ladder mount on habitat sub-frame
  • TIG welded new ladder mounting bar assembly
  • Match drilled pit-pin holes in new ladder mounting bar assembly
  • Sand blasted and painted new ladder mounting bar assembly
  • Wired and installed speedometer
  • Finished fabricating ladder wheel mounts
  • Sewed cloth cover for Fantastic vent fan plug
  • Received hall effect sending unit for speedometer
  • Sewed drawstring bag for portable propane stove regulator
  • Sewed drawstring bag for portable propane stove
  • Started designing transmission mount for speedometer sending unit
  • Started planning local test trips
  • Started populating truck with provisioning goods
  • Finished fabricating new folding entry ladder (new folding ladder also doubles as a step ladder)
  • Added footman’s loops under bed for securing cargo
  • Tested stowing and setting up sewing machine and OLFA cutting mat
  • Tested invertors and decided to purchase pure sine wave invertor
  • Tested hall effect sensor proximity range
  • Fabricated hall effect sensor mount for speedometer sending unit
  • Bench assembled and tested hall effect sensor assembly for speedometer
  • Installed hall effect sensor sending unit assembly for speedometer
  • Opened up padlock hole for securing spare tire
  • Designed bathroom door
  • Made bond test sample for bathroom door assembly
  • Working toward making final orders to prepare for departure
  • Calibrated speedometer using GPS and radar speed indicator
  • Purchased bathroom door material
Advertisements

Truck Update 4/14/19

  • Added additional heater duct in kitchen wall
  • Tested heater configuration
  • Increased max regulated engine speed from 2600 to 2750 rpm
  • Advanced engine injection timing by 2 degrees
  • Increased injection fuel delivery to ~170 hp setting
  • Tested driving performance after upgrades: noticeable improvement in hill climb / acceleration
  • Purchased tools and materials
  • Applied Wabi-Sabi Overland vinyl decals to habitat and truck
  • Drilled holes in water Jerry cans
  • Installed machined barb bulkhead fittings in water Jerry cans
  • Leak checked water Jerry cans
  • Stowed water Jerry cans in habitat
  • Received:
    • Front portal tank upgrades
    • Drive train boots
    • Portal axle fluid
  • Drove truck to heat up fluids
  • Drained transmission for 2nd fluid change
  • Drained front portal hubs
  • Removed front portal vents
  • Test fit new front portal reservoirs
  • Purchased:
    • Copper crush washers
    • Permatex for drive shaft boot install
  • Started making hardware kit for portal tank upgrade
  • Drilled holes in portal tank caps
  • Machined portal tank dipstick pins
  • Machined portal tank vent return tubes
  • Welded dipsticks
  • Welded vent return tubes
  • Turned down cap screws for inner most portal tank cover holes
  • Installed new front portal tanks
  • Plumbed front portal vents
  • Filled front portal vents
  • Drained residual fluid out of transmission
  • Sealed and installed transmission drain plugs
  • Removed old drive shaft boots
  • Prepped and installed new drive shaft boots
  • Refilled transmission with new fluid

Truck Update 4/7/19

  • Received shower plumbing fittings
  • Received entry door grab handle mount hardware
  • Received gray water tank hold down hardware
  • Cleaned and sealed driver side under subframe storage boxes
  • Riveted rubber Jerry can support bumpers
  • Started looking at injection pump adjustment access
  • Installed
    • Driver side under subframe mount
    • Under subframe storage boxes
    • Driver side Jerry cans
    • Gray water tank
  • Plumbed kitchen sink to gray water tank
  • Installed gray water tank vent tube
  • Installed gray water tank vent valve
  • Measured toilet vent fan splash guard area
  • Started laying out shower drain plumbing
  • Purchased additional plumbing parts for shower drain
  • Final installed air heater exhaust muffler
  • Secured air heater intake silencer
  • Ordered steel for rear bumper assembly
  • Recieved entry door grab handle
  • Fabricated toilet vent fan splash guard
  • Cut stainless steel screen for toilet vent fan splash guard
  • Final installed toilet vent fan splash guard
  • Started looking at habitat door hold open catch
  • Installed shower drain plumbing assembly
  • Connected shower drain to gray water tank
  • Fabricated external entry door grab handle mount assembly
  • Installed external entry door grab handle
  • Started looking at ladder storage
  • Started looking at passthrough door hold open catch
  • Located passthorugh door bump stop
  • Started designing forward internal entry door grab handle
  • Bench assembled electric air compressor to truck manifold
  • Received rear bumper material
  • Received tire air gauges
  • Finished fabricating forward internal grab handle components
  • Fabricated passthrough door bump stop
  • Fabricated bracket assembly for entry door hold open catch
  • Installed forward internal grab handle
  • Installed electric air compressor manifold onto truck
  • Installed footman’s loop in passthrough for door open catch
  • Bonded passthrough door bump stop
  • Installed entry door hold open catch bracket and footman’s loop
  • Cut steel for rear bumper tube
  • Tack welded full length of bumper tube
  • Final welded bumper tube joints
  • Cut clamp up tubes for mud flap bolts
  • Welded clamp up tubes into bumper
  • Fit checked bumper tube on truck
  • Primed and painted bumper tube
  • Stenciled fuel tank and Jerry cans
  • Reamed out mud flap bolt holes on bumper tube
  • Prepped weld location for bumper mount
  • Mounted bumper to truck
  • Touched up paint on bumper assembly
  • Cut rubber for mud flaps
  • Cut aluminium for mud flaps
  • Made bolt kit for mounting mud flaps
  • Put reflective tape on bumper
  • Installed mud guards and flaps

Truck Update 3/31/19

  • Removed forward gladhand line
  • Fit checked gray water tank and located sink drain fitting
  • Plumbed fuel line for pre-heater
  • Wired pre-heater and pre-heater pump
  • Test ran pre-heater
  • Ran speaker wire and tested speakers in cab
  • Installed Noico sound deadening mat over driver
  • Wired and tested GPS odometer
  • Started modifying gray water tank
  • Fit checked hose barbs on gray water tank
  • Mounted speakers in cab
  • Tested alternate pre-heater control switch
  • Decided to change pre-heater control to single switch instead of “smart controller”
  • Final wired pre-heater and tested pre-heater
  • Wired 12V compressor relay circuit (for future 24V compressor)
  • Reprogrammed GPS odometer to default to miles
  • Looked at hab entry door grab handle positions
  • Purchased gray water tank internal tubing
  • Sealed firewall passthrough hole
  • Added additional power ground location inside cab
  • Modified gray water barb fittings to better accommodate hose
  • Final assembled gray water tank
  • Labeled gray water tank with stencil
  • Clearanced gray water tank hold down and touched up paint
  • Organized tools
  • Cleaned storage boxes for under subframe on driver side
  • Started looking at under subframe storage locking options
  • Trimmed 12mm stainless air line for electric air compressor to truck interface
  • Cut metal for storage box lock mount
  • Welded lock assembly for under subframe storage boxes
  • Welded two footman’s loops for storage box anti-rattle strap
  • Clearanced back of under subframe storage box mount
  • Enlarged rivet holes for jerry can bumpers on under subframe storage box mount
  • Purchased shower drain tubing
  • Purchased paint for under subframe storage box mount
  • Sewed anti-rattle strap
  • Prepped, seam sealed, primed, and painted under subframe storage box mount

Truck Update 3/24/19

  • Reviewed fuel filter change and fuel bleed procedure
  • Worked on auxiliary systems fuel tank mounting design
  • Refreshed memory on how to:
    • Adjust max governed RPM
    • Advance engine injection timing
    • Increase injection pump fuel delivery
  • Reviewed engine pre-heater controller options
  • Removed engine components to gain access to fuel filters
  • Removed old fuel primer pump
  • Installed new fuel primer pump
  • Replaced both fuel filters
  • Bled fuel system
  • Reassembled removed engine components
  • Ran engine and checked for leaks
  • Tested out variety of way to access engine pump adjustment
  • Inspected air filter (nice and clean)
  • Trimmed interfering material away from gray water tank hold down
  • Prepped and primed gray water tank hold down
  • Seam sealed gray water tank hold down
  • Painted gray water tank hold down
  • Ordered gray water tank fittings
  • Reviewed heater and pre-heater fuel line hardware
  • Reviewed electric air compressor wiring
  • Reviewed pre-heater wiring
  • Reviewed speaker wiring diagram
  • Disconnected winch from truck batteries
  • Purchased small filter for diesel air heater
  • Drilled holes in fuel tank for heater and fuel heater fuel supply
  • Used magnets inside tubing to remove any metal particles from inside tank (it worked really well)
  • Trimmed fuel fitting standpipes to prevent heater from completely draining truck fuel tank
  • Mounted fuel fittings in fuel tank
  • Test ran electric air compressor
  • Installed air heater fuel pump
  • Finished air heater installation and purged air from fuel lines
  • Test ran air heater
  • Disposed of old engine coolant
  • Topped off engine coolant
  • Received gray water tank fittings
  • Test fit jam nut on power steering box (12M-1.5)
  • Extended wire length for speakers
  • Installed filter and fuel pump for engine pre-heater
  • Purchased switch for engine pre-heater
  • Ordered additional air heater ducting and swivel vent
  • Fabricated GPS odometer, compressor, and pre-heater switch bracket dash panel
  • Painted switch bracket dash panel
  • Bench assembled and installed switch bracket dash panel
  • Removed unneeded / redundant passenger seat lap belt
  • Tested out additional heater duct in kitchen (we will likely add more ducting)
  • Cut witness groove in end of power steering adjustment stud (to maintain original reference position)
  • Removed power steering adjustment jam nut and cleaned threads
  • Installed new seal and jam nut on power steering box
  • Adjusted steering slop out of power steering box
  • Test drove truck to check steering play
  • Washed truck

Truck Update 3/17/19

  • Received additional tool roll
  • Continued to organize tool rolls
  • Drained coolant
  • Removed old engine pre-heater (120V AC electric)
  • Relocated horn to accommodate new pre-heater
  • Shortened air compressor intake line (was rubbing on grill)
  • Lubricated and measured steering box adjustment stud size
  • Removed engine water pump outlet hose
  • Started looking for small power steering hose leak
  • Removed pre-heater outlet hose
  • Purchased and trimmed new radiator hoses
  • Purchased new steering adjustment jam nut
  • Purchased Zerex G05 50/50 coolant
  • Fabricated pre-heater mount brackets
  • Machined aluminum hose union
  • Removed brackets in engine bay that interfered with pre-heater
  • Installed new pre-heater brackets
  • Seam sealed and painted pre-heater mount assembly
  • Replaced lower radiator hose
  • Rerouted pre-heater inlet hose
  • Received fuel filters
  • Mounted pre-heater and finalized pre-heater plumbing
  • Refiled engine with Zerex G05 coolant
  • Secured pre-heater wiring
  • Started engine and burped coolant system
  • Test drove and evaluated fluids:
    • Nice firm brakes
    • Good engine temperature
    • Significant improvement in shifting with new fluid

Truck Update 3/10/19

  • Machined sink drain adapter
  • Installed sink drain and connected to drain hose
  • Tested sink drain and checked for leaks
  • Installed anti-rattle straps on under subframe storage boxes
  • Took measurements for driver side accessory palette
  • Started looking at design changes to our driver side accessory palette
  • Started sequencing and planning final phase of truck build
  • Moved truck back to shop
  • Drained engine oil, transmission fluid, and differential oil
  • Ordered fuel filters
  • Verified correct oil filters on hand
  • Verified correct replacement fluids and quantities
  • Reviewed brake bleeding procedure for power bleeder
  • Purchased engine oil
  • Ordered DOT4 brake fluid
  • Filled differentials with Redline 75W-90 (GL-5)
  • Drained transfer case
  • Drained engine oil filter
  • Replaced oil filter and filled engine with oil (Rotella 15W-40)
  • Torqued lug nuts
  • Removed and replaces clutch drain
  • Reduced tire pressure to 55psi
  • Fit checked auxiliary diesel tank
  • Identified small power steering hose leak
  • Disposed of unneeded oil
  • Test rain engine to check for leaks and oil level
  • Filled transmission with Redline MT-85 (GL-4)
  • Checked hubs, differentials, and clutch plug for oil leaks
  • Inspected steering linkages
  • Reviewed brake bleeding procedure in Mercedes manual
  • Inspected rubber drive shaft boots
  • Evaluated options for adjusting steering box
  • Disposed of additional oil
  • Picked up brake fluid
  • Bled brakes