Truck Update 9/16/18

  • Started habitat lift and scheduling
  • Purchased furniture dollies for moving habitat in shop
  • Coordinated with local crane company about habitat lift
  • Jacked up habitat and laced it on caster dollies
  • Moved habitat box to opposite side of shop
  • Started preparing for habitat lift
  • Lifted habitat onto subframe
  • Aligned, bonded, and bolted habitat to subframe
  • Installed
    • Rock guards
    • Rear fenders
    • Sand ladders
    • Passenger jerry can mount
    • Rear pintal
    • Shovel on roof rack
  • Removed protective film from outside of habitat
  • Installed spare tire on rear frame
Advertisements

Habitat Lift

Today was a big day for the project. We crane lifted our @totalcomposites habitat box onto our U1300L this evening. The habitat is temporarily sitting on wooden blocks, so it’s sitting about 4” higher than it will. We will be re-positioning and securing it to the torsion free subframe in the next few days.

Prep for Lift
Prep for Lift
Prep for Lift
Prep for Lift
Habitat Sitting on Our Truck for the First Time!
Habitat Sitting on Our Truck for the First Time!

Truck Update 9/9/18

  • Installed roof hatch spoiler
  • Adjusted door captures on habitat
  • Made templates for melamine on back wall of cab
  • Received grip tape and VHB
  • Laid out and cut melamine acoustic insulation for cab using templates
  • Applied grip tape to access ladders and steps
  • Melamine acoustic insulation bond test
  • Prepped and painted passenger side jerry can mount
  • Bonded melamine foam to rear cab wall
  • Truck cleaning session
  • Temporarily reinstalled driver seat
  • Reinstalled front grill
  • Prepped and coated tail lights with spar urethane

Truck Update 9/2/18

  • Ordered MC4 solar panel cable extensions
  • Machined copper bus bar
  • Purchased electrical boxes for solar wiring
  • Fit checked cable junction box on habitat roof
  • Milled back of electrical junction box flat
  • Received MC4 solar panel wires
  • Ordered MC4 15 amp solar panel fuses
  • Ordered gland nuts, ring terminals, and other electrical hardware
  • Started laying out large electrical junction box
  • Cut aluminum for roof wire hold down plates
  • Continued laying out large electrical junction box
  • Received gland nuts and ring terminals
  • Crimped and shrink wrapped 4 gauge ring terminal
  • Made gland nut template for junction box
  • Bored gland nut holes in junction box
  • Received MC4 15 amp inline fuses
  • Completed fabrication of junction box
  • Milled slots in aluminum roof wire hold down plates
  • Bonded junction box to roof
  • Deburred and applied VHB to roof wire hold down plates
  • Installed fuses and routed solar wires on roof
  • Fabricated junction box lid hold down plate
  • Final wired junction box
  • Closed out junction box
  • Final routed 4 gauge habitat power wires

Truck Update 8/26/18

  • Installed shovel mounts on front of roof rack
  • Installed bike enclosure aluminum plate on roof rack
  • Installed silicone bumpers between bike enclosure and cargo box
  • Looked for candidate locations for additional small fuel tank
  • Cleaned cab roof
  • Reinstalled roof hatch
  • Reinstalled roof rack
  • Met with Erik from Spin Imaging about vinyl graphics options
  • Machined aluminum spacers to level roof rack
  • Seam sealed roof rack joints
  • Final installed roof rack with thread sealer
  • Installed roof rack support struts
  • Sealed and riveted open holes in roof rack box lid
  • Installed roof rack boxes
  • Measured and laid out roof rack access ladders
  • Purchased steel for cab ladders
  • Cut steel for cab ladders
  • Sheared and rolled steel for upper ladder corners
  • Rotary table milled plate for upper ladder corners
  • Welded ladder corners into ring and cut into 4 pieces
  • Welded ladders
  • Fit checked ladders
  • Fabricated lower mount for ladders
  • Purchased paint for ladders
  • Fabricated passenger side ladder mount shim
  • Seam sealed ladder joints
  • Made RTV gaskets for ladder mounts
  • Made hardware kit for mounting ladders
  • Match drilled ladder mount holes into truck and roof rack
  • Installed door lock into habitat
  • Cab cleanup
  • Evaluated ergonomics of ladders while temporarily mounted to cab
  • Increased step area of lower 2 ladder rungs
  • Prepped, primed, and painted ladders
  • Mounted ladders

Truck Update 8/19/18

  • Welded shortened roof rack brackets
  • Opened up roof rack mount holes from 5/16″ to 3/8″
  • Drilled drain holes in roof rack rails
  • Fabricated diagonal roof rack braces
  • Fit checked roof rack mount brackets
  • Test fit diagonal roof rack braces
  • Laid out and cut expanded metal for side and back of bike enclosure cage
  • Received marker lights
  • Received auxiliary fuel tank locking filler neck
  • Received candidate gray water tank
  • Welded expanded metal to side and back of bike enclosure cage
  • Prepped, primed, and painted roof rack support struts
  • Prepped, primed, and painted roof rack mounting brakcets
  • Made hardware kits for mounting the roof rack
  • Final test fit folding bikes in roof rack
  • Removed roof hatch from cab
  • Looked at locations for candidate gray water tank
  • Cleaned, prepped, and painted roof hatch
  • Made hardware kit for mounting roof storage boxes
  • Ordered rubber shovel mounts for roof rack
  • Researched alternate heater fuel tanks
  • Received Seagull IV X-1F drinking water purifier
  • Received Planar 2D-12 diesel heater and accessories from Total Composites
  • Fabricated aluminum large area washers for roof rack box mount
  • Cut replacement fiber board insulation backing disc for roof hatch
  • Cut melamine acoustic foam for roof hatch insulation
  • Painted roof hatch backing board
  • Machined and weld prepped bike tie down tangs
  • Machined and weld prepped shovel attach plates
  • Assembled refurbished roof hatch
  • Added additional weather stripping seal around roof hatch edge
  • Finished all welding on roof rack
  • Ordered P clamps for bike enclosure
  • Fabricated aluminum plate for bike enclosure
  • Prepped, primed, and painted aluminum plate for bike enclosure
  • Prepped, primed, and painted roof rack

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