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
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