Truck Update 7/15/18

  • Organized electrical supplies
  • Wired marker lights on rear frame
  • Replaced 12V marker lights with 24V LED bulbs
  • Tested marker lights
  • Test fit rear frame
  • Increased rear frame hole clearance
  • Bonded and installed rear frame
  • Installed ladder on rear frame
  • Installed hoist side strut on rear frame
  • Final wired rear marker lights
  • Sealed forward and both side panel to extrusion joints with Korapop 225
  • Sealed roof to extrusion joints with Korapop 225
  • Researched folding bike options
  • Started reviewing roof rack layout modifications
  • Received BattleBorn batteries from Sunsense Solar
  • Fabricated rain guard for habitat side passthrough
  • Fabricated forward upper marker light rail
  • Mounted and wired forward upper marker lights
  • Replaced and operationally checked forward marker light bulbs with 24V LED
  • Placed reflective tape around upper corners of rear panel
  • Drilled and tapped rain guard mounting holes in habitat side passthrough frame
  • Bonded and installed rain guard with Korapop 225
  • Bonded forward upper marker light rail
    • We held the rail in place with 3M double sided tape while the Korapop 225 cured
  • Purchased reflectors for habitat
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Truck Update 7/8/18

  • Prepped, tacked, and welded on rear tire mount frame:
    • Marker light mounts
    • Upper driver side grab handle
    • Sand ladder mount studs
    • Tire mount plate assembly
    • Tire lift strap clearance slot
    • Ladder mount tabs
  • Final welded all tire mount frame structural joints
  • Welded sand ladder hold down nuts
  • Sandblasted, primed, and painted sand ladder hold down nuts
  • Final match drilled ladder to rear steel mount frame
  • Fabricated locking tab for spare tire
  • Ordered flooring samples
  • Ordered ARB awning
  • Ordered assorted electrical components and hardware for rear tire mount
  • Machined, sand blasted, primed, and painted tire locking plate
  • Welded tire locking tab to tire mount
  • Drilled solar wire passthrough holes in rear frame
  • Machined steel solar wire passthrough tube
  • Drilled, prepped, and welded in steel passthrough tube in upper frame beam
  • Received flooring smaples
  • Machined and welded to rear frame marker light wire guide mount tabs
  • Received ARB awning
  • Received from McMaster-Carr:
    • 4-gauge welding wire (for solar panels)
    • 3M VHB to mount solar panels
    • Assorted hardware
    • Aluminum tube for forward marker light mounts
    • Aluminum angle for mounting solar panels
    • Solar panel wire guide tube
  • Started ordering process for (3) lithium BattleBorn 100 Amp-Hr 10012 batteries
  • Machined nylon spacer sleeves for sand ladder mount
  • Machined aluminum sand ladder retaining caps
  • Test fit sand ladders on rear frame
  • Drilled mounting holes for wire support adel clamps
  • Cut aluminum solar wire guard tube
  • Prepped, masked, primed, and painted rear frame
  • Started solar panel mounting plan
  • Reviewed door installation instructions
  • Started prepping interior cabinets for painting
  • Started fabricating forward marker light mount
  • Final sealed rear habitat wall to extrusion joints with Korapop 225
  • Installed door in habitat

Truck Update 7/1/18

  • Drilled 2 1/2″ hole through floor for airhead composting toilet fan
  • Drilled and ran wiring from lower driver side corner to airhead composting toilet fan
  • Fixtured and clecoed lower 4 corner caps
  • Torqued and sealed all 4 wired gland nut bulkhead fittings
  • Milled outer round contour of spare tire mount plate
  • Fit checked spare tire mount plate on spare tire wheel hub
  • Milled side gussets for spare tire mount plate
  • Cut vertical rails to mount spare tire
  • Trimmed spare tire mounting lugs
  • Bonded forward upper driver side corner cap
  • Bonded 5 more corner caps
  • Received 12/24V LED fog lights
  • Received 12/24V size 194 LED marker light upgrade bulbs
  • Received 3 additional Grote amber marker lights
  • Bonded final 2 corner caps
  • Received 4 of 6 100W solar panels
  • Sand blasted plating off tire mount studs
  • Final welded tire mount plate
  • Received final 2 100W solar panels
  • Weld prepped tire mount plate support straps
  • Tack welded tire mount support strap assembly
  • Welded tire mount assembly onto rear frame
  • Drilled holes through rear frame for sand ladder mount studs
  • Reviewed battery options
  • Cut steel box beam for final tire mount structure
  • Removed clecos from corner caps
  • Countersunk cleco holes using aircraft microstop
  • Filled cleco holes with Korapop 225
  • Sealed all internal habitat joints using 225
  • Sealed forward driver side vertical joint using 225
  • Sealed habitat side passthrough frame joint with 225

Truck Update 6/24/18

  • Crimped and terminated heavy gauge wire for solar panels
  • Crimped and terminated wires in rear lower passenger corner
  • Started running driver side wiring
  • Started evaluating roof solar panel configurations
  • Selected solar panels
  • Finished running driver side wiring
  • Crimped and terminated wires in rear lower driver corner
  • Started securing wires in extrusion using acoustic foam
  • Ordered solar panels
  • Ordered 24V LED fog light replacements
  • Ordered gland nuts for habitat to exterior passthrough connections
  • Planned habitat wire penetration locations
  • Started planning air head toilet vent fan location and wiring
  • Finished securing wires in extrusion using acoustic foam
  • Received McMaster-Carr order
  • Started finalizing placement of air head composting toilet and vent
  • Spliced exterior wiring to go through gland nuts
  • Created cut template for interior over bed lighting
  • Test fit cabinet in several desired interior locations
  • Wired and installed over bed lighting
  • Purchased hole saws to finalize wiring for corner closeouts
  • Completed preliminary welding of spare tire mount plate
  • Painted tire hoist side strut
  • Milled mounting flat on upper sand ladder mount bolt
  • Dry installed all 4 external gland nuts
  • Fixtured and clecoed upper 4 corner caps

Truck Update 6/17/18

  • Organized and rearranged tools in shop
  • Sealed holes used to bond hardpoints on rear wall
  • Prepped around window openings for window install
  • Tested wire splicing technique
  • Receive McMaster-Carr order for tire mount hardware
  • Machines sand ladder mount studs
  • Taped out floor plan and cabinet positions
  • Re-taped butcher paper to floor of habitat
  • Verified interior dimensions
  • Updated power use spreadsheet
  • Started preliminary solar panel and battery selection
  • Drilled mounting bolt clearance holes in tire mount frame
  • Ordered tire mount bolts
  • Installed over bed windows
  • Installed over counter windows
  • Drilled and tapped mounting holes in rear panel hardpoints for mounting frame
  • Received McMaster-Carr order
  • Fit checked cargo access hatches
  • Tested 8 gauge wire crimper
  • Installed, clipped, and bonded access hatches
  • Installed weather stripping on access hatches
  • Wired and installed Fan-tastic vent
  • Measured roof area for solar panels
  • Machined marker light brackets for rear mount frame
  • Machined sand ladder hold down nut components
  • Checked continuity and re-labeled wires
  • Prepped, bonded, and clipped roof hatch
  • Rearranged truck parts storage room
  • Wired and finish installed roof hatch

Truck Update 6/10/18

  • Chamfered edges of rear wall panel
  • Prepped and bonded steel hardpoints in rear wall panel
  • Tack welded tire mount ladder brackets
  • Fabricated and test fit tire boom hoist side strut
  • Fit checked rear extrusions
  • Trimmed 1/8″ from upper and lower rear extrustions
  • Positioned tire mount on rear panel
  • Clearance checked tire mount with extrusions
  • Match drilled pilot holes for tire mount on rear panel
  • Cut and labeled wiring for installation of rear panel
  • Installed and wire wrapped rear panel wiring
  • Prepped and bonded lower extrusion to rear panel
  • Drilled wiring hole for fantastic fan
  • Repositioned rear panel on shop floor
  • Marked location of solar panel wire passthrough on roof
  • Planned rear wall bond sequence
  • Drilled wiring holes for interior spotlights
  • Drilled wiring hole in roof panel for solar wiring
  • Ran wiring on back edge of roof panel
  • Bonded driver side vertical extrusion on rear panel
  • Prepped and final bonded rear panel (last panel bond!)
  • Removed clamps from rear panel

Truck Update 6/3/18

  • Finalized layout of rear wall tire mount
  • Measured position of hardpoints in rear wall
  • Cut primary steel components for rear wall tire mount
  • Used wire wheel to remove scale and rust from tire mount steel
  • Measured and trimmed rear vertical extrusions
  • Cleaned and rough trimmed aluminum ladder for tire mount
  • Fit and weld prepped tire mount steel primary frame joints
  • Purchased paint for tire mount
  • Fabricated long shanked drill bit for wire runs
  • Drilled wire run hole in ceiling panel and side extrusion for roof hatch
  • Fit checked remaining wall extrustions
  • Clearanced upper fore-aft extrusions
  • Started structural welding on tire mount frame
  • Lifted roof panel
  • Tested new ignition keys
  • Adjusted engine idle
  • Verified function of air warning lights
  • Fit checked tire, ladder, and sand plates on tire mount frame
  • Started cutting secondary steel for tire mount frame
  • Fit checked water tank through habitat door
  • Laid back wall on floor for edge champhering
  • Fit checked, prepped, and bonded forward extrusion to roof panel
  • Started fabricating spare tire boom hoist for tire mount
  • Fit checked, prepped, and bonded side extrusions to roof panel
  • Finished fabricating spare tire boom hoist
  • Prepped and bonded roof panel