Truck Update: 10/14/18

Fabricated plates to secure center dash panel
Drilled and tapped center dash panel
Painted plates to secure center dash panel
Researched and selected fuse upgrade for winch wiring
Purchased hole saw for mounting deadbolt in passthrough door
Started bond prepping passthrough door parts
Marked out deadbolt location on passthrough door
Finished center dash panel installation
Sealed backup camera electrical connectors
Replaced backup camera bolts with proper grip
Secured air lines and wires on chassis
Cleaned and photographed data tags on pneumatic system
Cleaned underneath dash on driver side: brake, clutch, etc.
Researched air dryer cold climate systems
Drilled passthrough door deadbolt lock hole
Dry assembled and prepped passthrough door
Primed all passthrough door parts with Sika 205 activator
Final assembled passthrough door using Korapop 225
Masked and RTV sealed cab side passthrough frame
Measured for dynamat
Researched fusible links for house batteries
Cleaned passthrough bellows material
Prepped and cleaned passthrough frame
Installed passthrough bellows
Trimmed excess passthrough bellow material
Tested bonding passthrough material (EPDM) with Lord adhesive 7545 – mediocre bond strength
Installed passthrough door hinges
Trimmed passthrough door for better fit
Installed passthrough door
Started comparing hab interior structure options
Tested bonding passthrough bellow material (EPDM) with cyanoacrylate (super glue) – very good bond strength
Added weather stripping to passthrough door
Marked location of striker plate on passthrough door jam
Trimmed and bonded passthrough bellows
Installed passthrough door lock
Cut strike plate hole in passthrough door frame
Trimmed passthrough door hinge pin to length
Disposed of unneeded composite panel
Disposed of leftover roof rack material

A note about bonding passthrough bellows:

We got our passthrough bellows from Uni-grip, but they are also available from other suppliers like Total Composites. The bellows are made out of EPDM high density foam rubber. EPDM can be a little tricky to bond, and we tried several adhesives in tests. Cyanoacrylate (super glue) was by far the best and in tests; the rubber failed before the adhesive/bond. It’s actually pretty tricky to bond all of the corrugated bellows surface at the same time, so we found that the only practical way to bond the bellows was to bond one pleat at a time. We trimmed the bellows for a 1 1/4″ overlap.