March 2018 – Wabi-sabi Overland

Truck Update 3/25/18

Posted on March 25, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

Received kitchen cabinet and locks
Received and fit checked 2 1/2″ rear pintal
Began truck cab passthrough cutout planning
Measured roof rack
Researched roof rack cargo box options
Started stripping down kitchen cabinet for repaint
Started laying out passthrough door
Purchased low profile deadbolt lock for passthrough door
Cut aluminum for the passthrough door edging
Ordered cargo boxes for roof rack
Started laying out passthrough door panel
Removed unneeded material from inside cab back wall
Removed old insulation from cab roof hatch (23 7/8″ diameter)
Removed rear cab windows
Marked passthrough cut out in back of cab
Laminated plywood for passthrough door panel
Trimmed down height of kitchen cabinet
Marked trim line on and trimmed forward passthrough frame
Cut passthrough opening in back of cab
Fit checked forward passthrough frame opening
Removed passenger seat and unneeded sheet metal
Removed rear pintal (42 pound assembly)
Bonded aluminum facesheets to passthrough door panel
Purchased masonite for new roof hatch insulation mount
Started looking for new cab seats
Ordered insulation/sound deadening for cab rear wall and roof hatch
Started tack welding passthrough frame to cab

Rear Pintal for 2 1/2″ Receiver

Kitchen Cabinet Paint Prep

Passthrough Door Frame Fit Check

Removing Glass from Cab

Passthrough Cutout Planning

Removed Rear Pintal

Passthrough Fit Check

Passthrough Cutout Work in Progress

Passthrough Fit Check

Passthrough Door Bonding

Truck Update 3/18/18

Posted on March 18, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

One of the main reasons that we decided to make a new habitat for our truck was that we really wanted to incorporate a passthrough into the cab of the truck from the living area. Honestly, we’ve been a little overwhelmed by the logistics of designing and building a passthrough for a while. We figured that now would be the best time to finish the passthrough details before we start assembling the habitat box.

Wabi-Sabi Expedition Truck Passthrough Exploded View

We designed our passthrough to have a frame assembly on the cab side and a frame assembly with door opening into the habitat side. The frames are connected with a water tight EPDM rubber bellows / accordion seal. The cab side assembly is made of 3 steel frames and can be disassembled to disconnect the bellows from the cab if future engine or transmission work requires that the cab be tipped up. The primary cab side frame is welded to the back of the cab.

Wabi-Sabi Expedition Truck Passthrough

Wabi-Sabi Expedition Truck Passthrough Section

The habitat side frame is made of 2 steel frames and 1 aluminum frame. The aluminum frame incorporates the door hinge and lock strike plate. The door opens inwards into the shower/bathroom/entry area of the habitat. The door is made from a 1 1/2″ thick insulated RV door panel. The hab side steel frame is bonded to the forward wall of the habitat prior to habitat box assembly.

Talked with vendors about passthrough bellows material
Finished design of passthrough
Cut steel for passthrough frames
Cut aluminum RV door frame extrusion material for passthrough door frame
Welded habitat and cab side steel pasthrough frame
Milled slots for passthrough door hinges in aluminum frame
Milled steel corner fillets for bellows connection
Welded and finished fillets
Ordered passthrough bellows material (ED-5389 from Uni-Grip)
Primed and painted habitat exterior passthrough frame

Aluminum Passthrough Frame Assembly

Miter Cutting Aluminum Passthrough Frame

Miter Cut of Aluminum Passthrough Frame

Aluminum Passthrough Frame Corner Joint

Weld Prepped Aluminum Passthrough Frame Corner

Welded Aluminum Passthrough Frame Corner

Milling Hinge Slots in Aluminum Passthrough Frame

Milled Hinge Slot in Aluminum Passthrough Frame

Fit Check of Hinge on Aluminum Passthrough Frame

Fit Checking Steel and Aluminum Hab Side Frames

Steel Passthrough Frame Assemblies

Cut Steel for Passthrough Frames

Jigging Cab Side Steel Passthrough Frames

Welded Cab Steel Passthrough Inner and Outer Fames

Welded Steel Passthrough Frames

Milling Corner Fillets for Bellows Connection

Milled Corner Fillets for Bellows Connection

Hab and Cab Passthrough Frame Assemblies

Painted Hab Side Steel Frame

Truck Update: 3/11/18

Posted on March 11, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

Ordered and received tile
Ordered and received LED eyeball lights
Ordered and received under counter LED lights
Ordered kitchen cabinet and locks
Ordered 2 1/2″ receiver pintal
Purchased marine adhesive for floor hardpoint bonding
Created assembly sequence list
Started passthrough design work
Started electrical wiring plan
Inspected position of floor on subframe
Measured and inspected all panels and corner extrusions
Trimmed foam to fit in hardpoint channel
Dry fit forward lower extrusion and front panel
Marked position of passthrough on back of cab

Received LED Eyeball Lights

Under Counter LED Lights

Inspected Position of Floor on Subframe

Trimming Foam

Fitting Floor Foam

Dry Fit Forward Lower Extrusion

Dry Fit Front Panel

Marked Position of Passthrough on Back of Cab

Habitat Update 3/8/18

Posted on March 8, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

Another big day for the project: we received all of our windows and doors from Tern Overland today. We got everything but the roof hatch, and it should get here in a little over a week (and certainly before we need it!). We spent some time inventorying everything we received, and it all looks very good.

We are especially excited that everything is double glazed so our habitat should stay nice and cozy. All the windows have integrated blackout blinds and screens, too.

Euro Door

Large Over Counter Window

Window Locks and Struts

Cargo Access Door

Small Over Bed Window

Habitat Update 3/2/18

Posted on March 2, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

It’s a big day for the new habitat: our custom habitat kit from Total Composites arrived today! More details coming soon as we get into inventorying everything, but here are a few photos from the day.

We had 2 hours to unload the container, but with the 2 of us and a friend it took less than an hour to unload. Most of the panels are quite light and can be carried by 2 people. The floor panel weighs a bit and required all of us (including the truck driver) to carry it.

The container had a tamper free lock from U.S. customs on it. The truck driver didn’t have a bolt cutter and seemed concerned when he showed up. It took just a second to cut the lock off with an abrasive disc on a grinder.