Truck Update 5/20/18

  • Received Sika 205 Activator
  • Re-cut fillets in forward panel for passthrough frame (we changed our passthrough design after Total Composites cut our panel)
  • Fit checked passthrough frames
  • Added required fillets to passthrough cutout corners
  • Bond prepped forward passthrough cutout
  • Prepped passthrough frames using Sika 205 activator
  • Bonded in passthrough frames using Korapop 225
  • Cut steel for back wall hardpoints
  • Painted rock shields
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Truck Update 5/13/18

  • Fit checked forward wall panel again
  • Bond prepped and bonded forward wall
  • Trimmed scrap side wall panel for fixturing side wall extrusion bond
  • Fit checked and trimmed forward side wall extrusion
  • Marked and trimmed height of forward side wall extrusion
  • Bond prepped and bonded forward side wall extrusions
  • Clearance trimmed aft end of lower extrusions
  • Bond prepped and bonded driver side wall
  • Bond prepped and bonded passenger side wall

Truck Update 5/6/18

  • Started habitat assembly sequence planning
  • Sent out quote requests for water jet cutting aluminum roof hatch adapter plates (dedicated blog post about this topic to come in the future)
  • Inspected and touched up subframe paint
  • Laid habitat floor panel upside down on floor
  • Prepped habitat floor steel hardpoints for bonding
  • Dry fit hardpoints in floor
  • Rounded edges of hardpoint straps to ease foam installation
  • Bonded and installed hardpoints and foam in habitat floor panel
  • Drilled and tapped one central hole in each hardpoint to clamp
  • Re-positioned truck and habitat floor in shop for habitat assembly
  • Pilot drilled and tap drilled mount holes in habitat floor
  • Clearance drilled fiberglass at hardpoint holes
  • Tapped hardpoints in habitat floor
  • Reviewed bond primer requirements
  • Ordered Sika SP-205 (from EMI Supply) to prime aluminum to bond with Korapop 225.
  • Cut high density urethane foam blocks for floor support during habitat assembly
  • Bonded terry cloth to top of foam blocks with 3M 77
  • Removed clamps and temporary bolts from bonded hardpoints
  • Chamfered and cleaned lower edge of habitat floor panel
    • All panel edges had a lot of gel coat build up that needed to be removed and the edges needed to be softened. Previous fit checks show that this was a required step to get the panels to fit well in the extrusions.
  • Flipped, leveled, and positioned habitat floor panel
  • Chamfered and cleaned upper edge of habitat floor panel
  • Chamfered and cleaned all edges (including passthrough cutout) of forward panel
  • Rearranged panels and extrusions in shop space
  • Chamfered and cleaned all edges (including all cutouts) of left and right side panels
  • Dry fit checked all lower extrusions
  • Measured all panels and extrusions (again)
  • Checked flatness of floor on support blocks
  • Masked floor panel with heavy paper
  • Bond prepped and bonded forward lower extrusion using Korapur 140
  • Bonded several adhesive test samples using Korapur 140
  • Finalized order of water jet cut aluminum roof hatch adapter plates
  • Additional measurements and fit checking
  • Measured back wall panel height in preparation for cutting steel hardpoints
  • Bond prepped and bonded both side lower extrusions using Korapur 140

Truck Update 4/29/18

  • Removed fenders in preparation to paint subframe
  • Placed habitat floor panel on subframe
  • Match drilled all mounting holes through subframe into habitat floor
  • Made epoxy repair to small delaminated corner of habitat floor
  • Fit checked exhaust tubing downstream of muffler
  • Removed habitat floor panel from subframe
  • Finish welded exhaust and muffler
  • Continued subframe paint prep
  • Weld prepped subframe for spacer washers
  • Drilled all subframe to habitat bolt holes in frame rails
  • Welded spacer washers into place
  • Prepped and primed subframe
  • Received ignition key blanks
  • Painted subframe gloss black

Truck Update 4/22/18

  • Final installed cab inner passthrough frame
  • Ordered fender mount hardware
  • Disposed of old passenger bench seat
  • Cut square spacer washers for mid section of subframe under floor
  • Drilled oversized holes in spacer washers
  • Painted kitchen cabinet / pantry gloss white
  • Measured dimensions to make rock shield for top of rear fenders
  • Started laying out new position for muffler assembly
  • Started kitting muffler assembly parts
  • Ordered SBU OEM ignition key blanks from Expedition Imports
  • Welded muffler in new position
  • Removed aft under bed box mounts and jerry can mount in preparation for subframe painting
  • Fabricated exhaust and muffler mount brackets
  • Fabricated and match drilled rock shields for top of rear fenders
  • Welded on muffler bracket and bolted muffler mount bracket to old spare tire mount holes
  • Painted muffler mount
  • Removed driver side under bed storage mount in preparation for subframe painting

Truck Update 4/15/18

  • Received jerry cans
  • Received roof hatch from Tern Overland
  • Received new mechanical suspension cab seats
  • Updated roof hatch installation plan
  • Mocked up fender mounts
  • Mounted rear fenders to subframe
  • Started working to move muffler forward

 

 

Truck Update 4/8/18

  • Purchased steel for spare tire mount, subframe spacers, and back panel hardpoint inserts
  • Prepped, primed, and painted back wall of cab
  • Received drills and taps for subframe
  • Painted cab inner passthrough frame
  • Seam sealed all cab passthrough welds using Eastwood seam sealer
  • Applied second coat of paint on cab inner passthrough frame
  • Drilled 52 new 1/8″ diameter pilot holes in subframe
  • Final painted back wall of cab
  • Rearranged truck part storage area
  • Installed rear cab ceiling trim
  • Reinstalled rubber edge cover on back wall of cab
  • Removed cab headliner and inspected condition
  • Wiped down cab interior
  • Removed tail light brackets
  • Retorqued bolts that hold subframe to truck chassis (5 were so loose they could rotated by hand)
  • Moved tail lights aft to accommodate storage boxes
  • Relocated rear gladhands
  • Preliminary mounting of aft underbed storage
  • Prepped and painted back portion of truck frame