Truck Update 12/12/18

  • Ordered
    • Marmoleum flooring
  • Ordered and received
    • Hot water expansion tank
    • Small grab handle
    • Fire extinguishers
    • CO/Smoke detector
    • Indoor/outdoor thermal weather station
  • Started designing calorifier cabinet and refrigerator support
  • Started designing shower area divider
  • Applied first 2 coats of urethane to passenger side table
  • Paint stripped and cleaned candidate donor entry ladder
  • Reviewed geometry of entry ladder options
  • Started fabrication of candidate entry ladder
  • Fit checked candidate entry ladder
  • Fabricated candidate entry ladder
  • Final assembled candidate entry later
  • Test fit candidate entry ladder
  • Final coated urethane on passenger side table
  • Purchased material for shower area divider
  • Ordered
    • Caframo Sirocco II gimbal fan
    • Ground shore power electrical components
  • Laid out shower area divider on 3/4″ plywood
  • Rough cut shower area divider
  • Test fit shower area divider with passenger side table
  • Trimmed shower area divider
  • Rough cut FRP panel for shower area divider
  • Prepped and bonded FRP panel to shower area divider
  • Designed and ordered switch panel from Front Panel Express
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Truck Update 12/9/18

  • Test fit kitchen pantry
  • Masked, prepped, bonded, and screwed kitchen pantry
  • Made RTV gaskets for awning mount
  • Welded square nuts to stainless 6M all-thread for awning t-bolts
  • Machined and welded phillips drive extension
  • Sealed, bolted, and installed ARB awning
  • Fit checked, masked, prepped, bonded, and screwed headboard/cubby assembly
  • Routed square edges on oak plank for passenger side table
  • Bonded oak together for passenger side table
  • Received SurCal calorifier
  • Started water system layout
  • Started laying out alternate entry ladder
  • Tested samples of bathroom floor material
  • Started selecting plumbing components for hot water system
  • Cut passenger side oak table to size
  • Drilled wire passthrough hole in passenger side table top
  • Cut clearance for refrigerator in passenger side table top
  • Clearanced passenger side table top for wall structure
  • Final sanded surface of passenger side oak table top
  • Fit checked table in habitat
  • Took detail measurements for alternate ladder
  • Received and fit checked entry grab handle
  • Fit checked, prepped, and bonded bathroom cabinets

Truck Update 12/5/18

  • Received GPS backup speedometer
  • Received brake bleeder
  • Received shower fixture
  • Installed passenger side exterior wall table mount rail
  • Painted passenger side exterior wall table mount rail
  • Sealed bed rail support seams with paintable silicone
  • Located awning on exterior of habitat
  • Drilled awning mount holes
  • Fit checked, prepped, bonded, and screwed passenger overhead cabinet
  • Prepped and bonded awning mount plates
  • Received awning hardware from McMaster-Carr
  • Removed water tank from habitat to start designing tank mount
  • Test fit brake bleeder
  • Filled screw holes in bedroom wall
  • Made hair dryer plastic bubble heater for curing awning mount bond
  • Painted all exposed wood in bed area
  • Applied first coat of paint to rear passenger and driver side bed walls
  • Measured rear roof access ladder to ground clearance
  • Measured alternate habitat entry ladder height
  • Prepped, bonded, and screwed over bed cabinets on rear bed walls

Truck Update 12/2/18

  • Laid out passenger side countertop
  • Received self-adhesive carpet
  • Sanded and painted passenger side cabinet doors
  • Fabricated passenger side bed wall table mount
  • Sanded passenger cabinet/switch box assembly and headboard/cubby assembly in preparation for second coat of paint
  • Installed passenger side bed wall table mount
  • Applied first coat of paint to forward passenger side bed wall
  • Filled screw holes on back side of bed wall
  • Reinstalled engine access cover in cab
  • Applied final coat of paint on upper forward passenger side bed wall
  • Applied final coat of paint to
    • Passenger cabinet/switch box assembly
    • Headboard/cubby assembly
  • Prepped, bonded, and screwed rear over bed cabinet into habitat
  • Drilled hole for wire passthrough into breaker panel
  • Designed awning mount
  • Started evaluating door entry handle position
  • Ordered
    • Padded liners for pantry storage
    • Hardware for awning mount
  • Machines spacers for cabinet door latches
  • Machined mounting plates for awning
  • Milled down combination lock strike plates
  • Installed
    • Doors in passenger side overhead cabinet
    • Latches on passenger side overhead cabinet
  • Removed and epoxy installed all hardware on passenger side overhead cabinet
  • Applied self-adhesive carpet to inside of kitchen pantry
  • Installed strike plates on pantry combination locks with lock nuts
  • Fabricated
    • Passenger side exterior wall table mount rail
    • Drill guide for awning install
  • Rough cut oak for passenger side table top

Truck Update: 11/28/18

  • Ordered self-adhesive carpet for inside of cabinets
  • Bonded intermediate shelf for kitchen pantry
  • Bonded lower support rail to bed headboard
  • Laid out all headboard cubby areas
  • Cut all lumber for headboard cubby areas
  • Started bonding cubby components
  • Bonded cubby mount rails to back of headboard
  • Bonded cubby mount rails to bottom of cubby board
  • Predrilled holes for future cubby install into habitat
  • Fit checked headboard components
  • Finalized dimensions of passenger side storage and counter area
  • Cut plywood for cubby dividers
  • Modified headboard based on fit check
  • Bonded bottom cubby board to headboard
  • Bonded top trim on cubby dividers
  • Bonded cubby dividers to headboard
  • Belt sanded fore and aft edges of headboard for better fit
  • Designed breaker/switch panel and box
  • Cut lumber for breaker/switch box frame
  • Started assembling breaker/switch box frame
  • Finished assembling breaker/switch box frame
  • Fit checked headboard assembly and breaker/switch box frame in habitat
  • Clearanced breaker/switch box frame for window frame interference
  • Second fit check of breaker/switch box frame in habitat
  • Cut aluminum for breaker switch plate
  • Cut and bonded divider panel to breaker/switch box
  • Bonded breaker/switch box assembly to passenger side overhead cabinet
  • Filled, sanded, and paint prepped passenger side overhead cabinet/switch box assembly and headboard assembly
  • Applied first coat of paint to:
    • Passenger side overhead cabinet/switch box assembly
    • Headboard/cubby assembly

Truck Update 11/25/18

  • Inspected shim bond
  • Measured bed headboard area
  • Researched
    • Calorifiers
    • Expansion tanks
    • Footwear for travel
  • Finalized design for passenger side upper cabinet
  • Cut lumber for bed headboard and passenger side upper cabinet
  • Chamfered edges on all cut lumber
  • Cleaned up final painted pantry doors
  • Started bonding lumber for passenger side upper cabinet
  • Bonded upper trim for headboard
  • Ordered
  • Prepped, bonded, and screwed face on kitchen pantry
  • Prepped and bonded trim on side of kitchen pantry
  • Assembled components for face of passenger side upper cabinet
  • Installed locks on upper 3 pantry doors
  • Installed latches on lower 3 pantry doors
  • Installed polycarbonate plates on lockable pantry doors
  • Used tape to position pantry door faces while bonding with Korapop 225
  • Cut plywood base for passenger side upper cabinet
  • Assembled passenger side upper cabinet face
  • Assembled base and aft mount of passenger side upper cabinet
  • Final assembled overall passenger side upper cabinet
  • Looked at storage details inside pantry
  • Cut material for shelves and dividers for inside pantry
  • Fabricated and installed divider for passenger side upper cabinet
  • Cut plywood for bed headboard
  • Started bonding headboard assembly
  • Filled fastener holes in passenger side upper cabinet
  • Researched flooring options
  • Assembled upper pantry divider

We have the kitchen pantry just about ready to install in the habitat. We built the pantry around the face of a school locker that we salvaged. The face of the school locker was actually pretty nice with door jams, doors, hinges, locks, etc. The locker came with combination locks on the doors and although we didn’t want all of the doors lockable, we thought it might be nice to use some of the locks and have a few cabinets that we could secure if desired. One nice side benefits is that the locking mechanism is super secure, so we have higher confidence that the doors won’t rattle open when we are off-road. Now that we have the pantry finished and we get to step back and look at it, the combination locks look a little silly and we definitely didn’t need 3 lockable cabinets. They are a bit overkill, but hopefully we find them useful in the long run. If nothing else, it lets us show the interior of the habitat to strangers in the future while some of our personal items are secured away.

Truck Update 11/21/18

  • Cut shelves for pantry from 12mm plywood
  • Trimmed edges of pantry shelves with 3/4″ poplar
  • Measured and laid out shelf spacing
  • Bonded and screwed shelf ledges to pantry sides
  • Bonded edge trim to bathroom wall
  • Clearanced and trimmed pantry components
  • Dry assembled kitchen pantry and bathroom wall
  • Fabricated lower shelf and support structure for pantry
  • Bonded in all pantry shelves
  • Made and installed trim around top of pantry
  • Countersunk holes in cabinet face
  • Cleaned and deburred all screw holes
  • Filled all exposed screw holes
  • Sanded filling and paint prepped kitchen pantry
  • Received cabinet door latches
  • Purchased lumber to finish pantry
  • Applied first coat of paint to pantry
  • Applied first coat of pain on lumber to finish pantry
  • Sanded first coat of paint on pantry
  • Sprayed on second and third coats of pain to pantry
  • Sanded pantry doors
  • Started designing storage behind bed headboard
  • Cut and painted shims for spacing pantry from upper kitchen cabinet
  • Cut latch opening in pantry door faces
  • Applied second coat of paint on lumber to finish pantry
  • Started designing passenger side overhead cabinet
  • Painted pantry doors
  • Bonded 1/4″ spacers to upper kitchen cabinet
  • Purchased lumber for storage behind bed headboard and passenger side overhead cabinet
  • Applied final coat of paint on pantry doors