April 2018 – Wabi-sabi Overland

Truck Update 4/29/18

Posted on April 29, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

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

Removed Fenders in Preparation to Paint Subframe

Placed Floor Panel on Subframe

Match Drilled All Mounting Holes Through Subframe into Habitat Floor

Gear Offset Pancake Drill – Needed to Match Drill Subframe to Habitat Floor Locations

Fit Checked Exhaust Tubing Downstream of Muffler

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

Received Ignition Key Blanks

Subframe Paint Prepped

Subframe Primed

Subframe Painted

Truck Update 4/22/18

Posted on April 22, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

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

Cab Inner Passthrough Frame

Final Installed Cab Inner Passthrough Frame (1)

Final Installed Cab Inner Passthrough Frame (2)

Cab Inner Passthrough Frame Installed Detail

Final Installed Cab Inner Passthrough Frame (3)

Cut Square Spacer Washers

Drilled Oversized Holes in Spacer Washers

Spacer Washers

Rock Shield for Top of Rear Fenders

Match Drilled Rock Shields for Top of Rear Fenders

Rear Fender Rock Shield Part Kits

Painted Kitchen Cabinet

Exhaust and Muffler Modification Prep

Fabricated Exhaust and Muffler Mount Brackets

Muffler Mount Bracket

Welded Muffler Bracket and Bolted Mount to Old Spare Tire Mount Holes

Truck Update 4/15/18

Posted on April 15, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

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

Jerry Cans for Wabi-Sabi Overland

Received Roof Hatch from Tern Overland

Received New Mechanical Suspension Seats

Mocked Up Fender Mounts

Mounted Rear Fenders to Subframe

Removed Old Muffler

Truck Update 4/8/18

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

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

Steel for Mounts, Spacers, and Inserts on U1300L

U1300L Cab Passthrough Paint Prep

Painted Cab Interior Back Wall

Masking for Weld Seam Sealer

Sealed Welds on U1300L Cab

Painted Rear U1300L Cab Passthrough

Primed Cab Inner Passthrough Frame

Painted Cab Inner Passthrough Frame

U1300L Cab Back Wall Without Ceiling Trim

U1300L Cab Back Wall With Ceiling Trim

U1300L Rear Wall Rubber Edge Cover

Mounted After Underbed Storage

Moved Rear Tail Lights and Painted Rear Frame

Truck Update 4/1/18

Posted on April 1, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

Started welding passthrough frame to cab
Received pintal clamp bolt
Received acoustic foam
Received roof rack cargo boxes
Received aluminum trim for passthrough cab interior
Finished passthrough structural welding on exterior of cab
Ordered jerry cans
Ordered seats for cab
Marked subframe to hab floor bolt hole locations on subframe rails
Started subframe paint prep
Finished passthrough tig welding inside cab
Finished structural welding of passthrough frame on cab
Removed and disposed of foam from inside roof rack cargo boxes
Cleaned shop and recycled scrap material
Received bellows from Uni-Grip
Sketched out plates to fill cab back windows
CAD modeled plates to fill cab back windows
A friend was nice enough to plasma cut the plates to fill cab back windows: AeroDesign
Another friend gave us some Lord 7545 adhesive to try on the bellows: Monolith Aeroworks
Applied second coat of paint to habitat passthrough frame
Cut aluminum for cab passthrough trim
Drilled and tapped mounting holes for cab passthrough trim in cab side steel passthrough frame
Machined aluminum spacer for rear pintal shear bolt
Trimmed passthrough door
Rounded corners of cab side steel passthrough frame
Purchased abrasive disc for removing scale from subframe
Purchased black silicone to seal removable frame on cab passthrough
Continued removing scale from subframe
Drilled and tapped holes in cab passthrough frame for removable forward passthrough frame
Tack welded plates over old window openings
Started touch up paint on back of cab