Truck Update 8/12/18

  • Ordered and received folding bikes
    • Funny enough, after all the consideration, we placed an order for 2 Dahon Speed Uno folding bikes. We received one Dahon Speed Uno and one Dahon Speed P8.
  • Re-positioned habitat support foam blocks in preparation for future box lift
  • Preliminary planning for auxiliary fuel tank vent line
  • Took measurements for roof rack access ladders
  • Removed roof rack
  • Ordered and received shower floor (Thanks MK and FR!)
  • Purchased “prospector” tools
    • Shovel
    • Hatchet
    • Pruning Saw
  • Inspected roof hatch
  • Preliminary planning for next 2 months
  • Ordered Planar 2D-12 diesel heater and accessories from Total Composites
  • Made hardware kit for entry ladder mount bracket
  • Bolted entry ladder mount bracket to subframe
  • Blew hangar dust off of habitat and truck
  • Bonded raw wood test pieces with Korapop 225
  • Ordered auxiliary fuel tank locking filler neck
  • Ordered and received infrared pyrometer for portal axles
  • Ordered and received NPT weld on bungs for auxiliary fuel tank
  • Ordered candidate gray water tank
  • Ordered 2 additional marker lights
  • Ordered and received EGT gauge (SYL-1813-24) and K type thermocouple (TC-KEGT) from Auber Instruments
  • Ordered and received aluminum to mount Räskog cabinets
  • Researched water filtration options
  • Sealed final exterior habitat joints using Korapop 225
  • Ordered Seagull IV X-1F drinking water purifier
  • Created preliminary roof rack layout
  • Started fabricating new roof rack components
  • Laid out storage box mounting locations on roof rack
  • Removed roof rack brackets from U1300L cab roof
  • Removed hatch translation arm from U1300L cab
  • Rough cleaned U1300L cab roof
  • Cut down height of roof rack brackets by 2 1/2″
  • Removed unneeded steel from roof rack
  • Removed paint from roof rack for weld prep
  • Milled adjustment slots in roof rack brackets
  • Enlarged bolt holes from 5/16″ to 3/8″ in roof rack brackets
  • Fabricated roof rack support strut bracket
  • Fabricated tie down loop bracket plates
  • Fabricated ladder mount plates
  • Cut steel for storage box support structure
  • Purchased additional steel and paint for roof rack
  • Cut steel for bike enclosure cage
  • Fabricated, tacked, and TIG welded preliminary bike enclosure frame on roof rack
  • Match drilled cargo boxes to roof rack
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Secondary Transportation Options

We have debated for a long time about what kind of secondary transportation we would like. We decided early on that we did not want to tow our Jeep Wrangler behind us as we felt that the addition of a towed vehicle would really negatively influence our overall traveling enjoyment. That being said, we have always felt that having a secondary means of transportation was really important in the event of mechanical issues or even just the day to day benefit of being able to leave without having to break down camp just to run into “town” for groceries, sight-seeing, or to go on a nearby hike.

Suzuki 200

We spent a lot of time researching full size motorcycles like the Suzuki 200 and thinking about how we might take one with us on the truck. As you may have noted, the back of our truck is pretty well taken up by the large 365/80R20 spare tire, ladder, and sand ladders. We are also very conscious of the weight distribution of the vehicle, and we don’t want to overload the rear axle with the addition of a motorcycle supported on the rear hitch. We seriously considered mounting a motorcycle to the front hitch, but as we already have a large winch in the middle of the front bumper, the setup started looking pretty unrealistic when we got into the details.

CT70

In an attempt to lighten the load, we also considered older Honda Trail 70 and Trail 90 motorbikes. These classic smaller motorbikes were tempting, but were too small for 2 people and weren’t small enough to have 2 bikes on our truck.

We also considered electric assist bicycles, like the Unimoke, Super 73, or Buzzraw, as they are smaller than a gas powered motorbike and potentially give extended range when compared to a standard bicycle. They are very cool options and we were really tempted, but in the end, we decided that we didn’t want to deal with the added complexity of charging them. They may not do as well being stored outside and had similar storage / mounting issues to a gas powered motorbike. Realistically, they were probably too small for the 2 of us to comfortably ride any distance.

We circled back around to just wanting bicycles. We have been mountain bike people for years, but didn’t really like the idea of storing mountain bikes on the dusty, rear side of the truck. Having 2 size mountain bikes on the front of the truck just seemed like a claptrap we didn’t want to deal with. We opted to look into folding bikes that will be stored on our roof rack above the cab. Hopefully the roof rack will give them a bit of a cleaner environment that is out of harms way and potentially a little more theft resistant.

Dahon D7

We considered many brands and asked for advice from a lot of acquaintances that use folding bikes. We looked at Brompton, Dahon, and other Dahon knock-offs. We went and test rode several Dahon folding bikes and liked them quite a bit, but we felt that the cables of the multi-speed Dahon were very fiddly when folded and susceptible to being caught when we placed the bikes up on the roof rack. Having multiple speeds is without a doubt a huge performance benefit, but it comes with a little bit of complexity with a folding bike. Through this whole process, we were focused on simple, robust solutions.

Dahon Uno

We decided to go with very simple single speed Dahon Uno. They are small, light, and should handle being stored on the roof rack in the elements. They are certainly not as high performance as all of the above options, but they should hopefully meet our basic needs in a simple and reliable way.

Truck Update 7/29/18

  • Assembled 4 Råskog interior cabinets
  • Frosted cabinet glass using window film
  • Assembled kitchen locker
  • Touched up paint on kitchen locker
  • Paint prepped roof rack storage bins
  • Painted roof rack storage bins

Truck Update 7/22/18

  • Started planning interior wall attachment design
  • Reviewed feasibility of adding a small motorcycle or bicycles to our rig
  • Added side and rear colored reflectors
  • Fit checked solar panels on roof and verified mounting locations
  • Wired forward marker lights
  • Electrically tested end to end wiring of:
    • Marker lights
    • Over bed lights
    • Fantastic fan/vent
    • Roof hatch lights
    • Roof hatch motor
  • Replaced reflectors on sides of cab
  • Inspected fuel injection pump governor (RSV 350 type)
  • Finalized solar mounting plan
  • Started researching fuel injection pump governor setting
  • Prepped and painted cabinet doors
  • Broke down packaging for recycling
  • Verified engine, injection pump, and governor numbers
  • Prepped and painted cabinet sides, door pulls, and striker plates
  • Verified engine idle RPM and governed max RPM
  • Checked tachometer using manual strobotac
  • Prepped and painted cabinet backs and shelves
  • Fixed polarity on over bed LED reading lights
  • Researched injection pump tuning information
  • Purchased cabinet paint and cabinet door covering material
  • Priced bed support material at hardware store
  • Prepped and painted cabinet tops and bottoms
  • Fabricated all aluminum angle mounting brackets for solar panels
  • Attached mounting brackets to solar panels using 3M VHB #4952 and aluminum pop rivets
  • Bonded solar panels to roof of habitat using Korapop 225
    • Aluminum was primed using Sika 205
    • Panels were held in place during cure using 3M double sided tape
  • Cooked dinner using alcohol stove
    • We are trying different types of alcohol. Sunnyside alcohol had a really strong odor. Kleanstrip alcohol was odor free.
  • Continued researching backup transportation bicycle options
  • Started researching sideways slides for our Dometic refrigerator

Truck Update 7/15/18

  • Organized electrical supplies
  • Wired marker lights on rear frame
  • Replaced 12V marker lights with 24V LED bulbs
  • Tested marker lights
  • Test fit rear frame
  • Increased rear frame hole clearance
  • Bonded and installed rear frame
  • Installed ladder on rear frame
  • Installed hoist side strut on rear frame
  • Final wired rear marker lights
  • Sealed forward and both side panel to extrusion joints with Korapop 225
  • Sealed roof to extrusion joints with Korapop 225
  • Researched folding bike options
  • Started reviewing roof rack layout modifications
  • Received BattleBorn batteries from Sunsense Solar
  • Fabricated rain guard for habitat side passthrough
  • Fabricated forward upper marker light rail
  • Mounted and wired forward upper marker lights
  • Replaced and operationally checked forward marker light bulbs with 24V LED
  • Placed reflective tape around upper corners of rear panel
  • Drilled and tapped rain guard mounting holes in habitat side passthrough frame
  • Bonded and installed rain guard with Korapop 225
  • Bonded forward upper marker light rail
    • We held the rail in place with 3M double sided tape while the Korapop 225 cured
  • Purchased reflectors for habitat

Truck Update 7/8/18

  • Prepped, tacked, and welded on rear tire mount frame:
    • Marker light mounts
    • Upper driver side grab handle
    • Sand ladder mount studs
    • Tire mount plate assembly
    • Tire lift strap clearance slot
    • Ladder mount tabs
  • Final welded all tire mount frame structural joints
  • Welded sand ladder hold down nuts
  • Sandblasted, primed, and painted sand ladder hold down nuts
  • Final match drilled ladder to rear steel mount frame
  • Fabricated locking tab for spare tire
  • Ordered flooring samples
  • Ordered ARB awning
  • Ordered assorted electrical components and hardware for rear tire mount
  • Machined, sand blasted, primed, and painted tire locking plate
  • Welded tire locking tab to tire mount
  • Drilled solar wire passthrough holes in rear frame
  • Machined steel solar wire passthrough tube
  • Drilled, prepped, and welded in steel passthrough tube in upper frame beam
  • Received flooring smaples
  • Machined and welded to rear frame marker light wire guide mount tabs
  • Received ARB awning
  • Received from McMaster-Carr:
    • 4-gauge welding wire (for solar panels)
    • 3M VHB to mount solar panels
    • Assorted hardware
    • Aluminum tube for forward marker light mounts
    • Aluminum angle for mounting solar panels
    • Solar panel wire guide tube
  • Started ordering process for (3) lithium BattleBorn 100 Amp-Hr 10012 batteries
  • Machined nylon spacer sleeves for sand ladder mount
  • Machined aluminum sand ladder retaining caps
  • Test fit sand ladders on rear frame
  • Drilled mounting holes for wire support adel clamps
  • Cut aluminum solar wire guard tube
  • Prepped, masked, primed, and painted rear frame
  • Started solar panel mounting plan
  • Reviewed door installation instructions
  • Started prepping interior cabinets for painting
  • Started fabricating forward marker light mount
  • Final sealed rear habitat wall to extrusion joints with Korapop 225
  • Installed door in habitat

Truck Update 7/1/18

  • Drilled 2 1/2″ hole through floor for airhead composting toilet fan
  • Drilled and ran wiring from lower driver side corner to airhead composting toilet fan
  • Fixtured and clecoed lower 4 corner caps
  • Torqued and sealed all 4 wired gland nut bulkhead fittings
  • Milled outer round contour of spare tire mount plate
  • Fit checked spare tire mount plate on spare tire wheel hub
  • Milled side gussets for spare tire mount plate
  • Cut vertical rails to mount spare tire
  • Trimmed spare tire mounting lugs
  • Bonded forward upper driver side corner cap
  • Bonded 5 more corner caps
  • Received 12/24V LED fog lights
  • Received 12/24V size 194 LED marker light upgrade bulbs
  • Received 3 additional Grote amber marker lights
  • Bonded final 2 corner caps
  • Received 4 of 6 100W solar panels
  • Sand blasted plating off tire mount studs
  • Final welded tire mount plate
  • Received final 2 100W solar panels
  • Weld prepped tire mount plate support straps
  • Tack welded tire mount support strap assembly
  • Welded tire mount assembly onto rear frame
  • Drilled holes through rear frame for sand ladder mount studs
  • Reviewed battery options
  • Cut steel box beam for final tire mount structure
  • Removed clecos from corner caps
  • Countersunk cleco holes using aircraft microstop
  • Filled cleco holes with Korapop 225
  • Sealed all internal habitat joints using 225
  • Sealed forward driver side vertical joint using 225
  • Sealed habitat side passthrough frame joint with 225