Secondary Transportation Options

We have debated for a long time about what kind of secondary transportation we would like. We decided early on that we did not want to tow our Jeep Wrangler behind us as we felt that the addition of a towed vehicle would really negatively influence our overall traveling enjoyment. That being said, we have always felt that having a secondary means of transportation was really important in the event of mechanical issues or even just the day to day benefit of being able to leave without having to break down camp just to run into “town” for groceries, sight-seeing, or to go on a nearby hike.

Suzuki 200

We spent a lot of time researching full size motorcycles like the Suzuki 200 and thinking about how we might take one with us on the truck. As you may have noted, the back of our truck is pretty well taken up by the large 365/80R20 spare tire, ladder, and sand ladders. We are also very conscious of the weight distribution of the vehicle, and we don’t want to overload the rear axle with the addition of a motorcycle supported on the rear hitch. We seriously considered mounting a motorcycle to the front hitch, but as we already have a large winch in the middle of the front bumper, the setup started looking pretty unrealistic when we got into the details.

CT70

In an attempt to lighten the load, we also considered older Honda Trail 70 and Trail 90 motorbikes. These classic smaller motorbikes were tempting, but were too small for 2 people and weren’t small enough to have 2 bikes on our truck.

We also considered electric assist bicycles, like the Unimoke, Super 73, or Buzzraw, as they are smaller than a gas powered motorbike and potentially give extended range when compared to a standard bicycle. They are very cool options and we were really tempted, but in the end, we decided that we didn’t want to deal with the added complexity of charging them. They may not do as well being stored outside and had similar storage / mounting issues to a gas powered motorbike. Realistically, they were probably too small for the 2 of us to comfortably ride any distance.

We circled back around to just wanting bicycles. We have been mountain bike people for years, but didn’t really like the idea of storing mountain bikes on the dusty, rear side of the truck. Having 2 size mountain bikes on the front of the truck just seemed like a claptrap we didn’t want to deal with. We opted to look into folding bikes that will be stored on our roof rack above the cab. Hopefully the roof rack will give them a bit of a cleaner environment that is out of harms way and potentially a little more theft resistant.

Dahon D7

We considered many brands and asked for advice from a lot of acquaintances that use folding bikes. We looked at Brompton, Dahon, and other Dahon knock-offs. We went and test rode several Dahon folding bikes and liked them quite a bit, but we felt that the cables of the multi-speed Dahon were very fiddly when folded and susceptible to being caught when we placed the bikes up on the roof rack. Having multiple speeds is without a doubt a huge performance benefit, but it comes with a little bit of complexity with a folding bike. Through this whole process, we were focused on simple, robust solutions.

Dahon Uno

We decided to go with very simple single speed Dahon Uno. They are small, light, and should handle being stored on the roof rack in the elements. They are certainly not as high performance as all of the above options, but they should hopefully meet our basic needs in a simple and reliable way.

Truck Update 7/29/18

  • Assembled 4 Råskog interior cabinets
  • Frosted cabinet glass using window film
  • Assembled kitchen locker
  • Touched up paint on kitchen locker
  • Paint prepped roof rack storage bins
  • Painted roof rack storage bins

Truck Update 7/22/18

  • Started planning interior wall attachment design
  • Reviewed feasibility of adding a small motorcycle or bicycles to our rig
  • Added side and rear colored reflectors
  • Fit checked solar panels on roof and verified mounting locations
  • Wired forward marker lights
  • Electrically tested end to end wiring of:
    • Marker lights
    • Over bed lights
    • Fantastic fan/vent
    • Roof hatch lights
    • Roof hatch motor
  • Replaced reflectors on sides of cab
  • Inspected fuel injection pump governor (RSV 350 type)
  • Finalized solar mounting plan
  • Started researching fuel injection pump governor setting
  • Prepped and painted cabinet doors
  • Broke down packaging for recycling
  • Verified engine, injection pump, and governor numbers
  • Prepped and painted cabinet sides, door pulls, and striker plates
  • Verified engine idle RPM and governed max RPM
  • Checked tachometer using manual strobotac
  • Prepped and painted cabinet backs and shelves
  • Fixed polarity on over bed LED reading lights
  • Researched injection pump tuning information
  • Purchased cabinet paint and cabinet door covering material
  • Priced bed support material at hardware store
  • Prepped and painted cabinet tops and bottoms
  • Fabricated all aluminum angle mounting brackets for solar panels
  • Attached mounting brackets to solar panels using 3M VHB #4952 and aluminum pop rivets
  • Bonded solar panels to roof of habitat using Korapop 225
    • Aluminum was primed using Sika 205
    • Panels were held in place during cure using 3M double sided tape
  • Cooked dinner using alcohol stove
    • We are trying different types of alcohol. Sunnyside alcohol had a really strong odor. Kleanstrip alcohol was odor free.
  • Continued researching backup transportation bicycle options
  • Started researching sideways slides for our Dometic refrigerator

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

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