Yvonne @Quilting Jetgirl

Truck Update 12/23/18

Posted on December 23, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

Cleaned and organized shop
Tapped clamping hole in shower valve mount
Ordered additional electrical materials
Planned staged electrical system installation
Fabricated ground mounting plug hardware
Installed
- LED entry light
- Interior grab handle
- Passenger side LED under cabinet lights
- Kitchen LED under cabinet lights
- Ground power plug
- Shower valve mount
Touched up paint
Drilled wire runs in cabinets for LED lights
Ordered additional electrical components… again…
Started design of power bus bar mounting
Cut wire for main wire harness
Terminated wires for switch breaker panel
Received
- Switch breaker panel
- Electrical components
- Quick disconnects
Purchased shower plumbing components
Labeled all wire harness wires
Made breaker to switch jumpers
Reviewed battery monitor wiring
Test fit switch panel
Fabricated hot bus bar for switch panel
Started assembly of switch panel
Started consideration of modification of eating table
Finished switch panel assembly

Tapped clamping hole in shower valve mount

Installed shower valve mount

Installed LED entry light

Installed interior grab handle

Installed passenger side LED under cabinet lights

Installed kitchen LED under cabinet lights

Fabricated ground mounting plug hardware

Installed ground power plug

Received quick disconnects

Terminated wires for switch breaker panel

Received switch breaker panel

Labeled all wire harness wires

Made breaker to switch jumpers

Test fit switch panel

Fabricated hot bus bar for switch panel

Finished switch panel assembly

Started consideration of modification of eating table

Truck Update 12/18/18

Posted on December 19, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

Received marmoleum
Machined mounting plate for ground power plug
Enlarged mounting holes for pit pin tethers
Made heat shield for alcohol stove
Completed fabrication of calorifier cabinet assembly
Drilled holes in shower area divider for shower fixture
Drilled plumbing passthrough holes in calorifier cabinet assembly
Filled and sanded fastener holes in calorifier cabinet assembly
Prepped and applied first coat of paint to calorifier cabinet assembly
Installed
- Latches on kitchen upper cabinets
- Heat shield for stove
- Stove
- Slide out/cutting board
- Kitchen drawers
- Lower kitchen cabinet doors
- Sink
- Kitchen filtered water faucet
- Entry ladder pit pins
Fit checked Sirocco II fan in bed area
Drilled hole and bonded mounting for ground power plug
Sealed edge of FRP panel with epoxy and micro balloons
Masked and urethaned red oak edge trim on shower area divider
Started designing and cutting stock for shower valve mounts
Started designing and fabricating interior ground power plug mount
Finished machining interior cap for ground power plug mount
Finished machining shower valve mount
Rounded corners of interior grab handle
Ordered gel goat wax and water disconnect fittings
Test fit, masked, prepped, bonded, and screwed shower area divider and passenger side table

Received Marmoleum

Machined mounting plate for ground power plug

Drilled hole and bonded mount ring for ground power plug

Made heat shield for alcohol stove

Drilled holes in shower area divider for shower fixture

Prepped and applied first coat of paint to calorifier cabinet assembly

Prep for habitat work day

Installed latches on kitchen upper cabinets

Kitchen lower cabinet installation sequence-heat shield for stove, stove, slide out cutting board, drawers, doors, sink

Silicone installed kitchen sink

Assembled kitchen lower cabinet

Installed entry ladder pit pins

Sealed edge of FRP panel with epoxy and micro balloons

Masked and urethaned red oak edge trim on shower area divider

Started designing and fabricating interior ground power plug mount

Started designing and cutting stock for shower valve mounts

Finished machining shower valve mount

Fabricated spreader plate for internal grab handle mount

Rounded corners of interior grab handle

Fabricated spreader plate for internal grab handle mount

Test fit, masked, prepped, bonded, and screwed shower area divider and passenger side table

Truck Update 12/16/18

Posted on December 16, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

Trimmed FRP panel to edge of shower area divider
Started laying out cabinet on shower area divider
Researched house diesel tank options
Sanded and applied final coat of paint on bed walls
Clearanced passenger side table mount rail for wire clearance
Tested new ladder installation with multiple people
Evaluated kitchen backsplash material
Evaluated entry ladder as rear ladder extension
Received
- Sirocco II fan
- Ground power plug
- Inline GFI brekers
- Ground power outlet strip
Bonded oak trim to shower area divider
Added wall bonding flange to shower area divider
Cut entry light hold in shower area divider
Planned entry grab handle location on shower area divider
Started fabricating calorifier enclosure / refrigerator support
Evaluated storage outboard of calorifier
Started laying out hot water plumbing routing
Checked subframe clearance for engine coolant to calorifier
Tested out ratcheting jacks for possible habitat stabilizing
Drilled holes for grab handle mount in shower area divider
Ordered grab handle mount hardware
Ordered most wiring and electrical connector components
Ordered temporary 12V power supply
Started laying out shower plumbing
Started assembly of calorifier enclosure / refrigerator support
Cut hole for refrigerator power socket
Received
- Additional 12V power plugs
- Pit pins for entry ladder
- Temporary power supply
- Wire
- Additional electrical components

Notes on Project Productivity and Motivation

We’ve done a lot of projects like this over the years, and it is interesting to look back and note how project enthusiasm and motivation were affected by the way that we planned and executed the activity. An example would be doing all of the dirty work at the beginning of a project and having everything kitted and organized for a fun assembly at the end of a project when we are getting tired. It also helps to notice trends over the years. Sometimes a week or two will go by of really difficult, discouraging design and planning work. However, that time then causes several weeks of very easy and motivating progress. Progress is progress, even if sometimes it’s not visual progress. We have found that the biggest lessons we have learned over the years are to stay organized, plan ahead, and almost no matter what, work on the project at least a little bit each day. Even just 15 minutes a day keeps the momentum going.

That being said, this week was a little slow and frustrating researching options and trying to source systems parts. Hopefully the coming weeks will have the emotional payoff of a bunch of visual progress.

Trimmed FRP panel to edge of shower area divider

Clearanced passenger side table mount rail for wire clearance

Clearanced passenger side table mount rail for wire clearance and applied final coat of paint on bed walls

Evaluated kitchen backsplash material

Received Sirocco II fan

Received ground power plug

Received inline GFI breakers

Received ground power outlet strip

Added wall bonding flange to shower area divider

Bonded oak trim to shower area divider

Cut entry light hole in shower area divider

Planned entry grab handle location on shower area divider

Started fabricating calorifier enclosure-refrigerator support

Cut hole for refrigerator power socket

Started fabricating calorifier enclosure-refrigerator support

Received additional 12V power plugs

Received pit pins for entry ladder

Received temporary power supply

Received wire

Received additional electrical components

Truck Update 12/12/18

Posted on December 12, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

Ordered
- Marmoleum flooring
Ordered and received
- Hot water expansion tank
- Small grab handle
- Fire extinguishers
- CO/Smoke detector
- Indoor/outdoor thermal weather station
Started designing calorifier cabinet and refrigerator support
Started designing shower area divider
Applied first 2 coats of urethane to passenger side table
Paint stripped and cleaned candidate donor entry ladder
Reviewed geometry of entry ladder options
Started fabrication of candidate entry ladder
Fit checked candidate entry ladder
Fabricated candidate entry ladder
Final assembled candidate entry later
Test fit candidate entry ladder
Final coated urethane on passenger side table
Purchased material for shower area divider
Ordered
- Caframo Sirocco II gimbal fan
- Ground shore power electrical components
Laid out shower area divider on 3/4″ plywood
Rough cut shower area divider
Test fit shower area divider with passenger side table
Trimmed shower area divider
Rough cut FRP panel for shower area divider
Prepped and bonded FRP panel to shower area divider
Designed and ordered switch panel from Front Panel Express

Ordered and received hot water expansion tank

Anti-return valve for calorifier

Ordered and received small grab handle

Ordered and received CO-smoke detector

Ordered and received indoor-outdoor thermal weather station

Started designing calorifier cabinet and refrigerator support

Dometic CFX-40W refrigerator

Fabricated spacer washers for ladder upper bracket

Fabricated and installed ladder upper bracket and top step

Fabricated upper and lower ladder caps

Fixtured and welded ladder subframe mount

Ladder components prior to final assembly

Drilled ball detent pin holes in ladder mount

Fit checked candidate entry ladder

Fabricated and installed wheels to allow ladder to move with sway of truck

Finished entry ladder

Laid out shower area divider on plywood

Final cut shower area divider

Rough cut FRP panel for shower area divider

Prepped and bonded FRP panel to shower area divider using 2 part urethane

Applied first 2 coats of urethane to passenger side table

Test fit passenger side table

Test fit shower area divider with passenger side table

Designed and ordered switch panel from Front Panel Express

Truck Update 12/9/18

Posted on December 9, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

Test fit kitchen pantry
Masked, prepped, bonded, and screwed kitchen pantry
Made RTV gaskets for awning mount
Welded square nuts to stainless 6M all-thread for awning t-bolts
Machined and welded phillips drive extension
Sealed, bolted, and installed ARB awning
Fit checked, masked, prepped, bonded, and screwed headboard/cubby assembly
Routed square edges on oak plank for passenger side table
Bonded oak together for passenger side table
Received SurCal calorifier
Started water system layout
Started laying out alternate entry ladder
Tested samples of bathroom floor material
Started selecting plumbing components for hot water system
Cut passenger side oak table to size
Drilled wire passthrough hole in passenger side table top
Cut clearance for refrigerator in passenger side table top
Clearanced passenger side table top for wall structure
Final sanded surface of passenger side oak table top
Fit checked table in habitat
Took detail measurements for alternate ladder
Received and fit checked entry grab handle
Fit checked, prepped, and bonded bathroom cabinets

Test fit kitchen pantry

Masked, prepped, bonded, and screwed kitchen pantry

Made RTV gaskets for awning mount

Welded square nuts to stainless 6M all-thread for awning t-bolts

Sealed, bolted, and installed ARB awning

Machined and welded phillips drive extension

Fit checked, masked, prepped, bonded, and screwed headboard-cubby assembly

Routed square edges on oak plank for passenger side table

Bonded oak together for passenger side table

Cut and clearanced passenger side oak table to size

Fit checked passenger side table in habitat

Received SureCal calorifier

Fit checked, prepped, and bonded bathroom cabinets

Truck Update 12/5/18

Posted on December 5, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

Received GPS backup speedometer
Received brake bleeder
Received shower fixture
Installed passenger side exterior wall table mount rail
Painted passenger side exterior wall table mount rail
Sealed bed rail support seams with paintable silicone
Located awning on exterior of habitat
Drilled awning mount holes
Fit checked, prepped, bonded, and screwed passenger overhead cabinet
Prepped and bonded awning mount plates
Received awning hardware from McMaster-Carr
Removed water tank from habitat to start designing tank mount
Test fit brake bleeder
Filled screw holes in bedroom wall
Made hair dryer plastic bubble heater for curing awning mount bond
Painted all exposed wood in bed area
Applied first coat of paint to rear passenger and driver side bed walls
Measured rear roof access ladder to ground clearance
Measured alternate habitat entry ladder height
Prepped, bonded, and screwed over bed cabinets on rear bed walls

Received GPS backup speedometer

Received shower fixture

Received brake bleeder

Fit checked brake bleeder

Installed and painted passenger side exterior wall table mount rail

Located awning on exterior of truck and drilled awning mount holes

Fit checked, prepped, bonded, and screwed passenger overhead cabinet

Prepped and bonded awning mount plates

Made hair dryer plastic bubble heater for curing awning mount bond

Painted all exposed wood in bed area

Prepped, bonded, and screwed overbed cabinets on rear bed walls

Truck Update 12/2/18

Posted on December 2, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

Laid out passenger side countertop
Received self-adhesive carpet
Sanded and painted passenger side cabinet doors
Fabricated passenger side bed wall table mount
Sanded passenger cabinet/switch box assembly and headboard/cubby assembly in preparation for second coat of paint
Installed passenger side bed wall table mount
Applied first coat of paint to forward passenger side bed wall
Filled screw holes on back side of bed wall
Reinstalled engine access cover in cab
Applied final coat of paint on upper forward passenger side bed wall
Applied final coat of paint to
- Passenger cabinet/switch box assembly
- Headboard/cubby assembly
Prepped, bonded, and screwed rear over bed cabinet into habitat
Drilled hole for wire passthrough into breaker panel
Designed awning mount
Started evaluating door entry handle position
Ordered
- Padded liners for pantry storage
- Hardware for awning mount
Machines spacers for cabinet door latches
Machined mounting plates for awning
Milled down combination lock strike plates
Installed
- Doors in passenger side overhead cabinet
- Latches on passenger side overhead cabinet
Removed and epoxy installed all hardware on passenger side overhead cabinet
Applied self-adhesive carpet to inside of kitchen pantry
Installed strike plates on pantry combination locks with lock nuts
Fabricated
- Passenger side exterior wall table mount rail
- Drill guide for awning install
Rough cut oak for passenger side table top

Laid out passenger side countertop

Fabricated passenger side bed wall table mount

Installed passenger side bed wall table mount

Applied first coat of paint to forward passenger side bed wall

Applied final coat of paint to passenger side cabinet-switch box assembly

Appied final coat of paint to headboard-cubby assembly

Prepped, bonded, and screwed rear over bed cabinets into habitat

Drilled hole for wire passthrough into breaker panel

Evaluated awning mount options

Machined mounting plates for awning

Milled down combination lock strike plates

Installed doors in passenger side overhead cabinet

Machined spacers for cabinet door latches

Installed latches on passenger side overhead cabinet

Received self-adhesive carpet

Applied self-adhesive carpet to inside of kitchen pantry

Fabricated passenger side exterior wall table mount rail

Fabricated drill guide for awning install

Rough cut oak for passenger side table top

Truck Update: 11/28/18

Posted on November 28, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

Ordered self-adhesive carpet for inside of cabinets
Bonded intermediate shelf for kitchen pantry
Bonded lower support rail to bed headboard
Laid out all headboard cubby areas
Cut all lumber for headboard cubby areas
Started bonding cubby components
Bonded cubby mount rails to back of headboard
Bonded cubby mount rails to bottom of cubby board
Predrilled holes for future cubby install into habitat
Fit checked headboard components
Finalized dimensions of passenger side storage and counter area
Cut plywood for cubby dividers
Modified headboard based on fit check
Bonded bottom cubby board to headboard
Bonded top trim on cubby dividers
Bonded cubby dividers to headboard
Belt sanded fore and aft edges of headboard for better fit
Designed breaker/switch panel and box
Cut lumber for breaker/switch box frame
Started assembling breaker/switch box frame
Finished assembling breaker/switch box frame
Fit checked headboard assembly and breaker/switch box frame in habitat
Clearanced breaker/switch box frame for window frame interference
Second fit check of breaker/switch box frame in habitat
Cut aluminum for breaker switch plate
Cut and bonded divider panel to breaker/switch box
Bonded breaker/switch box assembly to passenger side overhead cabinet
Filled, sanded, and paint prepped passenger side overhead cabinet/switch box assembly and headboard assembly
Applied first coat of paint to:
- Passenger side overhead cabinet/switch box assembly
- Headboard/cubby assembly

Bonded intermediate shelf for kitchen pantry

Bonded lower support rail to be headboard

Laid out all headboard cubby areas

Cut all lumber for headboard cubby areas

Started bonding cubby components

Bonded cubby mount rails to back of headboard

Bonded cubby mount rails to bottom cubby board

Predrilled holes for future cubby install into habitat

Fit checked headboard and cubby components in habitat

Cut plywood for cubby dividers

Bonded top trim on cubby dividers

Bonded cubby dividers to headboard

Designed breaker-switch panel box

Started assembling breaker-switch box frame

Fit checked headboard assembly in habitat

Clearanced breaker-switch box for window frame interference

Second fit check of breaker-switch box frame in habitat

Cut aluminum for breaker switch plate

Bonded breaker-switch box assembly to passenger side overhead cabinet

Applied first coat of paint to passenger side overhead cabinet-switch box assembly

Applied first coat of paint to headboard-cubby assembly

Truck Update 11/25/18

Posted on November 25, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

Inspected shim bond
Measured bed headboard area
Researched
- Calorifiers
- Expansion tanks
- Footwear for travel
Finalized design for passenger side upper cabinet
Cut lumber for bed headboard and passenger side upper cabinet
Chamfered edges on all cut lumber
Cleaned up final painted pantry doors
Started bonding lumber for passenger side upper cabinet
Bonded upper trim for headboard
Ordered
- SureCal 22 litre calorifier
- GPS to check/calibrate speedometer
- Shower head, hose, and valve assembly
- Black label brake bleeder
Prepped, bonded, and screwed face on kitchen pantry
Prepped and bonded trim on side of kitchen pantry
Assembled components for face of passenger side upper cabinet
Installed locks on upper 3 pantry doors
Installed latches on lower 3 pantry doors
Installed polycarbonate plates on lockable pantry doors
Used tape to position pantry door faces while bonding with Korapop 225
Cut plywood base for passenger side upper cabinet
Assembled passenger side upper cabinet face
Assembled base and aft mount of passenger side upper cabinet
Final assembled overall passenger side upper cabinet
Looked at storage details inside pantry
Cut material for shelves and dividers for inside pantry
Fabricated and installed divider for passenger side upper cabinet
Cut plywood for bed headboard
Started bonding headboard assembly
Filled fastener holes in passenger side upper cabinet
Researched flooring options
Assembled upper pantry divider

We have the kitchen pantry just about ready to install in the habitat. We built the pantry around the face of a school locker that we salvaged. The face of the school locker was actually pretty nice with door jams, doors, hinges, locks, etc. The locker came with combination locks on the doors and although we didn’t want all of the doors lockable, we thought it might be nice to use some of the locks and have a few cabinets that we could secure if desired. One nice side benefits is that the locking mechanism is super secure, so we have higher confidence that the doors won’t rattle open when we are off-road. Now that we have the pantry finished and we get to step back and look at it, the combination locks look a little silly and we definitely didn’t need 3 lockable cabinets. They are a bit overkill, but hopefully we find them useful in the long run. If nothing else, it lets us show the interior of the habitat to strangers in the future while some of our personal items are secured away.

Prepped, bonded, and screwed face on kitchen pantry

Bonded trim on side of kitchen pantry

Installed locks on upper 3 pantry doors and latches on lower 3 pantry doors

Installed polycarbonate on lockable pantry doors

Used tape to position pantry door faces while bonding with Korapop 225

Headboard and passenger side upper cabinet design

Cut lumber for bed headboard and passenger side upper cabinet

Started bonding lumber for passenger side upper cabinet

Assembled components for face of passenger side upper cabinet

Assembled passenger side upper cabinet face

Assembled base of passenger side upper cabinet

Final assembled overall passenger side upper cabinet

Cut material for shelves and dividers for inside pantry

Fabricated and installed divider for passenger side upper cabinet

Filled fastener holes in passenger side upper cabinet

Cut plywood for bed headboard

Started bonding headboard assembly

Assembled upper pantry divider

Truck Update 11/21/18

Posted on November 21, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

Cut shelves for pantry from 12mm plywood
Trimmed edges of pantry shelves with 3/4″ poplar
Measured and laid out shelf spacing
Bonded and screwed shelf ledges to pantry sides
Bonded edge trim to bathroom wall
Clearanced and trimmed pantry components
Dry assembled kitchen pantry and bathroom wall
Fabricated lower shelf and support structure for pantry
Bonded in all pantry shelves
Made and installed trim around top of pantry
Countersunk holes in cabinet face
Cleaned and deburred all screw holes
Filled all exposed screw holes
Sanded filling and paint prepped kitchen pantry
Received cabinet door latches
Purchased lumber to finish pantry
Applied first coat of paint to pantry
Applied first coat of pain on lumber to finish pantry
Sanded first coat of paint on pantry
Sprayed on second and third coats of pain to pantry
Sanded pantry doors
Started designing storage behind bed headboard
Cut and painted shims for spacing pantry from upper kitchen cabinet
Cut latch opening in pantry door faces
Applied second coat of paint on lumber to finish pantry
Started designing passenger side overhead cabinet
Painted pantry doors
Bonded 1/4″ spacers to upper kitchen cabinet
Purchased lumber for storage behind bed headboard and passenger side overhead cabinet
Applied final coat of paint on pantry doors