Truck Update 3/31/19

  • Removed forward gladhand line
  • Fit checked gray water tank and located sink drain fitting
  • Plumbed fuel line for pre-heater
  • Wired pre-heater and pre-heater pump
  • Test ran pre-heater
  • Ran speaker wire and tested speakers in cab
  • Installed Noico sound deadening mat over driver
  • Wired and tested GPS odometer
  • Started modifying gray water tank
  • Fit checked hose barbs on gray water tank
  • Mounted speakers in cab
  • Tested alternate pre-heater control switch
  • Decided to change pre-heater control to single switch instead of “smart controller”
  • Final wired pre-heater and tested pre-heater
  • Wired 12V compressor relay circuit (for future 24V compressor)
  • Reprogrammed GPS odometer to default to miles
  • Looked at hab entry door grab handle positions
  • Purchased gray water tank internal tubing
  • Sealed firewall passthrough hole
  • Added additional power ground location inside cab
  • Modified gray water barb fittings to better accommodate hose
  • Final assembled gray water tank
  • Labeled gray water tank with stencil
  • Clearanced gray water tank hold down and touched up paint
  • Organized tools
  • Cleaned storage boxes for under subframe on driver side
  • Started looking at under subframe storage locking options
  • Trimmed 12mm stainless air line for electric air compressor to truck interface
  • Cut metal for storage box lock mount
  • Welded lock assembly for under subframe storage boxes
  • Welded two footman’s loops for storage box anti-rattle strap
  • Clearanced back of under subframe storage box mount
  • Enlarged rivet holes for jerry can bumpers on under subframe storage box mount
  • Purchased shower drain tubing
  • Purchased paint for under subframe storage box mount
  • Sewed anti-rattle strap
  • Prepped, seam sealed, primed, and painted under subframe storage box mount
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Truck Update 3/24/19

  • Reviewed fuel filter change and fuel bleed procedure
  • Worked on auxiliary systems fuel tank mounting design
  • Refreshed memory on how to:
    • Adjust max governed RPM
    • Advance engine injection timing
    • Increase injection pump fuel delivery
  • Reviewed engine pre-heater controller options
  • Removed engine components to gain access to fuel filters
  • Removed old fuel primer pump
  • Installed new fuel primer pump
  • Replaced both fuel filters
  • Bled fuel system
  • Reassembled removed engine components
  • Ran engine and checked for leaks
  • Tested out variety of way to access engine pump adjustment
  • Inspected air filter (nice and clean)
  • Trimmed interfering material away from gray water tank hold down
  • Prepped and primed gray water tank hold down
  • Seam sealed gray water tank hold down
  • Painted gray water tank hold down
  • Ordered gray water tank fittings
  • Reviewed heater and pre-heater fuel line hardware
  • Reviewed electric air compressor wiring
  • Reviewed pre-heater wiring
  • Reviewed speaker wiring diagram
  • Disconnected winch from truck batteries
  • Purchased small filter for diesel air heater
  • Drilled holes in fuel tank for heater and fuel heater fuel supply
  • Used magnets inside tubing to remove any metal particles from inside tank (it worked really well)
  • Trimmed fuel fitting standpipes to prevent heater from completely draining truck fuel tank
  • Mounted fuel fittings in fuel tank
  • Test ran electric air compressor
  • Installed air heater fuel pump
  • Finished air heater installation and purged air from fuel lines
  • Test ran air heater
  • Disposed of old engine coolant
  • Topped off engine coolant
  • Received gray water tank fittings
  • Test fit jam nut on power steering box (12M-1.5)
  • Extended wire length for speakers
  • Installed filter and fuel pump for engine pre-heater
  • Purchased switch for engine pre-heater
  • Ordered additional air heater ducting and swivel vent
  • Fabricated GPS odometer, compressor, and pre-heater switch bracket dash panel
  • Painted switch bracket dash panel
  • Bench assembled and installed switch bracket dash panel
  • Removed unneeded / redundant passenger seat lap belt
  • Tested out additional heater duct in kitchen (we will likely add more ducting)
  • Cut witness groove in end of power steering adjustment stud (to maintain original reference position)
  • Removed power steering adjustment jam nut and cleaned threads
  • Installed new seal and jam nut on power steering box
  • Adjusted steering slop out of power steering box
  • Test drove truck to check steering play
  • Washed truck

Truck Update 3/17/19

  • Received additional tool roll
  • Continued to organize tool rolls
  • Drained coolant
  • Removed old engine pre-heater (120V AC electric)
  • Relocated horn to accommodate new pre-heater
  • Shortened air compressor intake line (was rubbing on grill)
  • Lubricated and measured steering box adjustment stud size
  • Removed engine water pump outlet hose
  • Started looking for small power steering hose leak
  • Removed pre-heater outlet hose
  • Purchased and trimmed new radiator hoses
  • Purchased new steering adjustment jam nut
  • Purchased Zerex G05 50/50 coolant
  • Fabricated pre-heater mount brackets
  • Machined aluminum hose union
  • Removed brackets in engine bay that interfered with pre-heater
  • Installed new pre-heater brackets
  • Seam sealed and painted pre-heater mount assembly
  • Replaced lower radiator hose
  • Rerouted pre-heater inlet hose
  • Received fuel filters
  • Mounted pre-heater and finalized pre-heater plumbing
  • Refiled engine with Zerex G05 coolant
  • Secured pre-heater wiring
  • Started engine and burped coolant system
  • Test drove and evaluated fluids:
    • Nice firm brakes
    • Good engine temperature
    • Significant improvement in shifting with new fluid

Truck Update 3/10/19

  • Machined sink drain adapter
  • Installed sink drain and connected to drain hose
  • Tested sink drain and checked for leaks
  • Installed anti-rattle straps on under subframe storage boxes
  • Took measurements for driver side accessory palette
  • Started looking at design changes to our driver side accessory palette
  • Started sequencing and planning final phase of truck build
  • Moved truck back to shop
  • Drained engine oil, transmission fluid, and differential oil
  • Ordered fuel filters
  • Verified correct oil filters on hand
  • Verified correct replacement fluids and quantities
  • Reviewed brake bleeding procedure for power bleeder
  • Purchased engine oil
  • Ordered DOT4 brake fluid
  • Filled differentials with Redline 75W-90 (GL-5)
  • Drained transfer case
  • Drained engine oil filter
  • Replaced oil filter and filled engine with oil (Rotella 15W-40)
  • Torqued lug nuts
  • Removed and replaces clutch drain
  • Reduced tire pressure to 55psi
  • Fit checked auxiliary diesel tank
  • Identified small power steering hose leak
  • Disposed of unneeded oil
  • Test rain engine to check for leaks and oil level
  • Filled transmission with Redline MT-85 (GL-4)
  • Checked hubs, differentials, and clutch plug for oil leaks
  • Inspected steering linkages
  • Reviewed brake bleeding procedure in Mercedes manual
  • Inspected rubber drive shaft boots
  • Evaluated options for adjusting steering box
  • Disposed of additional oil
  • Picked up brake fluid
  • Bled brakes

Truck Update 3/3/19

  • Measured for shield plates over rear wheels
  • Fabricated stainless steel rear wheel shield plates
  • Received tool roll
  • Started organizing tools
  • Purchased material for dinette foot rest
  • Inventoried and back filled missing tools
  • Fabricated dinette foot rest
  • Prepped, masked, and bond installed dinette foot rest
  • Purchased flex lines for under sink fresh water pump assembly
  • Made plywood mounting palette for under sink fresh water pump assembly
  • Tested cold weather performance of habitat using small space heater
  • Habitat was rained on heavily: no leaks
  • Sewed ratchet straps for under subframe box anti-rattle
  • Fit checked under sink pump assembly
  • Painted plywood mounting palette for under sink pump assembly
  • Bench assembled water pump system
  • Fit checked all under sink systems and located under sink pump assembly
  • Drilled pilot hole for under sink drain
  • Drilled 1″ hole for under sink drain and installed drain hose
  • Drilled hole and installed tube for fresh water vent
  • Bonded on stainless steel over tire rock shields
  • Installed fresh water tank corral
  • Installed water pump system
  • Installed water filter
  • Connected fresh water quick disconnect
  • Connected faucet to water filter
  • Wired and tested water pump

Truck Update 2/24/19

  • Fit checked and installed left and right bed decks
  • Wired and tested bed deck ventilation fans
  • Installed overhead storage bins
  • Installed stove alcohol cans
  • Installed Froli star bed springs
  • Installed mattress
  • Checked ergonomics of bed height
  • Test fit custom quilt
  • Looked at priorities for next phase of truck work
  • Measured and cut plywood for seat backs
  • Bonded and trimmed 1″ foam on seat back panels
  • Cut and painted support for aft dinette seat back
  • Measured water pump mount area
  • Measured, fabricated, and painted wire chase cover for over head board
  • Fabricated stand offs for water pump mount
  • Installed water pump mount standoffs under sink
  • Installed support for aft dinette seat back
  • Upholstered dinette seat backs
  • Installed dinette seat backs
  • Installed wire chase cover

 

Truck Update 2/17/19

  • Prewired GFCI breakers on bench
  • Made mounting brackets for inverters
  • Drilled mounting holes in under bed storage bins
  • Finished all heater duct work
  • Installed inverters
  • Installed GFCI breakers
  • Tested all 120V AC systems
  • Cleaned underbed area
  • Test fit driver side bed deck
  • Picked location for overhead storage bins on bottom of bed deck
  • Installed underbed storage bins
  • Carpeted exposed surfaces in underbed cargo area
  • Secured refrigerator power plug
  • Mounted overhead storage bins to underside of drive side bed deck
  • Installed electrical distribution panel polycarbonate shield
  • Fabricated cargo net top mounting angle
  • Installed cargo net mounting angle
  • Installed cargo net
  • Purchased supplies from hardware store