Yvonne @Quilting Jetgirl

Truck Update: 10/7/18

Posted on October 7, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

Removed blank plug from dash for reverse camera shutoff switch
Modified blanking plate for reverse camera shutoff switch
Started body working forward passenger fender
Installed rear camera display switch
Test fit passthrough accordion seal
Measured cab interior light switch position
Fabricated cab interior light switch bracket
Installed cab interior light switch bracket and switch
Received sound deadening floor mats from Atkinson Vos
Finished cab light installation
Rounded sharp corners of passthrough frame
Tested cab audio system with USB MP3 files
Final mounted marker light relay under dash
Capped off unneeded audio wires in cab
Stowed 24V marker light wires in cab
Finished body working forward passenger fender
Prepped, primed, and painted forward passenger fender
Rewired ground wiring for winch
Secured all winch wiring
Rewired cab stereo and speakers

Modified Dash Blanking Plate and Installed Reverse Camera Shutoff Switch

Test Fit Passthrough Accordion Seal

Fabricated, Installed, and Tested Cab Interior Light Switch Bracket and Switch

Received Sound Deadening Floor Mats from Atkinson Vos

Body Worked, Prepped, Primed, and Painted Forward Passenger Fender

Rewired Ground Wiring for Winch and Secured All Winch Wiring

Tested Cab Audio System with USB MP3 Files

Truck Update 10/2/2018

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

Thanks for all the help this week, Dale!

Trimmed sand ladder spacers for better fit
Injection pump correspondence
Installed EGT gauge in exhaust manifold
Inspected turbocharger
Fabricated and painted EGT gauge mount bracket
Disassembled dash to gain wiring access
Ran power for EGT gauge from tachometer circuit breaker
Final installed EGT gauge
Ran power off of 12V converter for backup camera
Installed backup camera and monitor on dash
Replaced faulty power plug on backup camera monitor
Started troubleshooting cab side marker light wiring
Shortened reverse camera monitor mount height
Finalized reverse camera installation
Final wired all habitat marker lights
Final wired fog lights
Let the smoke out of several 24V rated LED bulbs in marker lights. Evidently they were not rated for 24V.
Continued troubleshooting cab side marker light wiring
Added a 24V triggered 12V supply relay to power all marker lights
Capped and terminated unneeded military light wires
Reassembled dash and organized all wiring harnesses

Trimmed Sand Ladder Spacers for Better Fit

U1300L OM366A Engine Inspection

Installed EGT Gauge in Exhaust Manifold

Disassembled Dash to Gain Wiring Access

Installed Backup Camera

Fabricated EGT Gauge Mount

Installed EGT Gauge Monitor

Final Wired Headlights, Foglights, and Marker Lights

Truck Update 9/23/18

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

Inquired about purchasing a subset of the U1300L sound deadening kit from Atkinson Vos
Inspected winch power cables
Inquired with several companies about fuel injection pump upgrade options
Ordered and received small, temporary habitat ventilation fan for airing out habitat
Purchased indoor/outdoor carpet for areas inside cab
Tested alternate adhesive for melamine foam
Started making lists of provisioning goods for trips
- Ordered and received JBL Charge 3 speaker for cab and habitat
- Ordered and received walkie talkies
- Purchased mosquito head netting
Fabricated lower aft marker light brackets
Fabricated backup camera mount
Replaced fog lights with new LED lights
Bonded on lower rear marker light
Installed passenger side LED external strip light
Picked location for:
- EGT gauge readout
- Backup camera monitor
Final wired passenger side LED external strip light
Started wiring lower aft marker lights

Temporary Habitat Ventillation Fan

Indoor-Outdoor Carpet for Cab

JBL Charge 3 Speaker

Walkie Talkies

Mosquito Head Netting

Fabricated Lower Aft Marker Light Brackets

Installed LED Bulbs in Lower Aft Marker Lights

Fabricated Backup Camera Mount

Replaced Fog Lights with New LED Lights

Bonded on Lower Rear Marker Lights

Installed Passenger Side LED External Strip Light

Final Wired Passenger Side LED External Strip Light

Started Wiring Lower Aft Marker Lights

Truck Update 9/16/18

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

Started habitat lift and scheduling
Purchased furniture dollies for moving habitat in shop
Coordinated with local crane company about habitat lift
Jacked up habitat and laced it on caster dollies
Moved habitat box to opposite side of shop
Started preparing for habitat lift
Lifted habitat onto subframe
Aligned, bonded, and bolted habitat to subframe
Installed
- Rock guards
- Rear fenders
- Sand ladders
- Passenger jerry can mount
- Rear pintal
- Shovel on roof rack
Removed protective film from outside of habitat
Installed spare tire on rear frame

Furniture Dollies for Moving Habitat in Shop

Habitat to Subframe Bolt Hole Alignment Check

Preventing Springs from Expanding While Jacking Habitat for Final Placement

Bonding Habitat to Subframe with 3M VHB

A Total of 49 Grade 8 Bolts Ready to Secure Habitat to Subframe

Sealing and Bonding Habitat to Subframe Bolts with Korapop 225

Final Bolting Habitat to Subframe

Installed Rear Rock Shield

Installing Rear Rock Shield

Rear Rock Shield Mount Area

Sand Ladder Mounts

Sand Ladder Installed

Checking Ergonomics of Cargo Access

Passenger Side Jerry Can Mount Area

Installed Passenger Side Jerry Can Mount

Rear Receiver

Rear Pintal Installed

Installed Shovel on Roof Rack

Removing External Protective Plastic Film

Installing Spare Tire on Rear Frame

Installed Spare Tire on Rear Frame

Current Truck Configuration

Habitat Lift

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

Today was a big day for the project. We crane lifted our @totalcomposites habitat box onto our U1300L this evening. The habitat is temporarily sitting on wooden blocks, so it’s sitting about 4” higher than it will. We will be re-positioning and securing it to the torsion free subframe in the next few days.

Habitat Sitting on Our Truck for the First Time!

Truck Update 9/9/18

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

Installed roof hatch spoiler
Adjusted door captures on habitat
Made templates for melamine on back wall of cab
Received grip tape and VHB
Laid out and cut melamine acoustic insulation for cab using templates
Applied grip tape to access ladders and steps
Melamine acoustic insulation bond test
Prepped and painted passenger side jerry can mount
Bonded melamine foam to rear cab wall
Truck cleaning session
Temporarily reinstalled driver seat
Reinstalled front grill
Prepped and coated tail lights with spar urethane

Installed Roof Hatch Spoiler

Adjusted Door Captures on Hab

Made Templates for Melamine on Back of Cab Wall

Laid Out and Cut Malamine for Back of Cab Wall

Melamine Acoustic Insulation Bond Test

Bonded Melamine Foam to Rear Cab Wall

Received Grip Tape

Applied Grip Tape to Access Ladders and Steps

Prepped and Painted Passenger Side Jerry Can Mount

Prepped and Coated Tail Lights with Spar Urethane

Truck Ready for Habitat Lift

Truck Update 9/2/18

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

Ordered MC4 solar panel cable extensions
Machined copper bus bar
Purchased electrical boxes for solar wiring
Fit checked cable junction box on habitat roof
Milled back of electrical junction box flat
Received MC4 solar panel wires
Ordered MC4 15 amp solar panel fuses
Ordered gland nuts, ring terminals, and other electrical hardware
Started laying out large electrical junction box
Cut aluminum for roof wire hold down plates
Continued laying out large electrical junction box
Received gland nuts and ring terminals
Crimped and shrink wrapped 4 gauge ring terminal
Made gland nut template for junction box
Bored gland nut holes in junction box
Received MC4 15 amp inline fuses
Completed fabrication of junction box
Milled slots in aluminum roof wire hold down plates
Bonded junction box to roof
Deburred and applied VHB to roof wire hold down plates
Installed fuses and routed solar wires on roof
Fabricated junction box lid hold down plate
Final wired junction box
Closed out junction box
Final routed 4 gauge habitat power wires

Machined Copper Bus Bar MS27212

Machined Copper Bus Bar

Received MC4 Solar Panel Wires

Fabricated Aluminum Roof Wire Hold Down Plates

Received Gland Nuts

Crimped and Shrink Wrapped 4 Gauge Ring Terminals

Made Gland Nut Template for Junction Box

Bored Gland Nut Holes in Junction Box

Completed Fabrication of Junction Box

Received MC4 15 Amp Inline Fuses

Final Wired Junction Box

Fabricated Junction Box Lid Hold Down Plate

Closed Out Junction Box

Final Routed 4 Gauge Habitat Power Wires

Milled Back of Electrical Junction Box

Final Routed 4 Gauge Habitat Power Wires

Truck Update 8/26/18

Posted on August 26, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

Installed shovel mounts on front of roof rack
Installed bike enclosure aluminum plate on roof rack
Installed silicone bumpers between bike enclosure and cargo box
Looked for candidate locations for additional small fuel tank
Cleaned cab roof
Reinstalled roof hatch
Reinstalled roof rack
Met with Erik from Spin Imaging about vinyl graphics options
Machined aluminum spacers to level roof rack
Seam sealed roof rack joints
Final installed roof rack with thread sealer
Installed roof rack support struts
Sealed and riveted open holes in roof rack box lid
Installed roof rack boxes
Measured and laid out roof rack access ladders
Purchased steel for cab ladders
Cut steel for cab ladders
Sheared and rolled steel for upper ladder corners
Rotary table milled plate for upper ladder corners
Welded ladder corners into ring and cut into 4 pieces
Welded ladders
Fit checked ladders
Fabricated lower mount for ladders
Purchased paint for ladders
Fabricated passenger side ladder mount shim
Seam sealed ladder joints
Made RTV gaskets for ladder mounts
Made hardware kit for mounting ladders
Match drilled ladder mount holes into truck and roof rack
Installed door lock into habitat
Cab cleanup
Evaluated ergonomics of ladders while temporarily mounted to cab
Increased step area of lower 2 ladder rungs
Prepped, primed, and painted ladders
Mounted ladders

Installed Shovel Mounts on Front of Roof Rack

Installed Bike Enclosure Aluminum Plate on Roof Rack

Installed Silicone Bumpers Between Bike Enclosure and Cargo Box

Machined Aluminum Spacers to Level Roof Rack

Reinstalled Roof Rack

Installed Roof Rack Support Struts

Reinstalled Roof Hatch

Installed Roof Rack Support Struts

Sealed and Riveted Open Holes in Roof Rack Box Lid

Installed Roof Rack Boxes

Installed Door Lock into Habitat

Measured and Laid Out Roof Rack Access Ladders

Cut Steel for Cab Ladders

Rotary Table Milled Plate for Upper Ladder Corners

Sheared and Rolled Steel for Upper Ladder Corners

Welded Ladder Corners into Ring and Cut into 4 Pieces

Welded Ladders

Increased Step Area of Lower 2 Ladder Rungs

Made RTV Gaskets and Hardware Kit for Ladder Mounts

Prepped, Primed, and Painted Ladders

Match Drilled Ladder Mount Holes into Truck and Roof Rack

Mounted Ladders

Truck Update 8/19/18

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

Welded shortened roof rack brackets
Opened up roof rack mount holes from 5/16″ to 3/8″
Drilled drain holes in roof rack rails
Fabricated diagonal roof rack braces
Fit checked roof rack mount brackets
Test fit diagonal roof rack braces
Laid out and cut expanded metal for side and back of bike enclosure cage
Received marker lights
Received auxiliary fuel tank locking filler neck
Received candidate gray water tank
Welded expanded metal to side and back of bike enclosure cage
Prepped, primed, and painted roof rack support struts
Prepped, primed, and painted roof rack mounting brakcets
Made hardware kits for mounting the roof rack
Final test fit folding bikes in roof rack
Removed roof hatch from cab
Looked at locations for candidate gray water tank
Cleaned, prepped, and painted roof hatch
Made hardware kit for mounting roof storage boxes
Ordered rubber shovel mounts for roof rack
Researched alternate heater fuel tanks
Received Seagull IV X-1F drinking water purifier
Received Planar 2D-12 diesel heater and accessories from Total Composites
Fabricated aluminum large area washers for roof rack box mount
Cut replacement fiber board insulation backing disc for roof hatch
Cut melamine acoustic foam for roof hatch insulation
Painted roof hatch backing board
Machined and weld prepped bike tie down tangs
Machined and weld prepped shovel attach plates
Assembled refurbished roof hatch
Added additional weather stripping seal around roof hatch edge
Finished all welding on roof rack
Ordered P clamps for bike enclosure
Fabricated aluminum plate for bike enclosure
Prepped, primed, and painted aluminum plate for bike enclosure
Prepped, primed, and painted roof rack

Welded Shortened Roof Rack Brackets

Painted Roof Rack Mounting Brackets

Fabricated Diagonal Aluminum Roof Rack Braces

Painted Roof Rack Support Struts

Received Marker Lights

Fabricated aluminum large area washers for roof rack box mount

Roof rack box hardware mount kit

Test Fit Roof Rack Boxes

Removed Roof Hatch from Cab

Paint prep for roof hatch

Painted Roof Hatch

Fabricated roof hatch backing board and melamine insulation

Assembled refurbished roof hatch

Received Seagull IV X-1F drinking water purifier

Received Planar 2D-12 diesel heater

Received Planar 2D-12 diesel heater accessories

Received Auxiliary Tank Locking Filler Neck

Received rubber shovel mounts for roof rack

Hardware Kit for Roof Rack Shovel Mounts

Hardware kit for aluminum bike enclosure plate

Painted Roof Rack

Fabricated and painted aluminum plate for bike enclosure

Truck Update 8/12/18

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

Ordered and received folding bikes
- Funny enough, after all the consideration, we placed an order for 2 Dahon Speed Uno folding bikes. We received one Dahon Speed Uno and one Dahon Speed P8.
Re-positioned habitat support foam blocks in preparation for future box lift
Preliminary planning for auxiliary fuel tank vent line
Took measurements for roof rack access ladders
Removed roof rack
Ordered and received shower floor (Thanks MK and FR!)
Purchased “prospector” tools
- Shovel
- Hatchet
- Pruning Saw
Inspected roof hatch
Preliminary planning for next 2 months
Ordered Planar 2D-12 diesel heater and accessories from Total Composites
Made hardware kit for entry ladder mount bracket
Bolted entry ladder mount bracket to subframe
Blew hangar dust off of habitat and truck
Bonded raw wood test pieces with Korapop 225
Ordered auxiliary fuel tank locking filler neck
Ordered and received infrared pyrometer for portal axles
Ordered and received NPT weld on bungs for auxiliary fuel tank
Ordered candidate gray water tank
Ordered 2 additional marker lights
Ordered and received EGT gauge (SYL-1813-24) and K type thermocouple (TC-KEGT) from Auber Instruments
Ordered and received aluminum to mount Räskog cabinets
Researched water filtration options
Sealed final exterior habitat joints using Korapop 225
Ordered Seagull IV X-1F drinking water purifier
Created preliminary roof rack layout
Started fabricating new roof rack components
Laid out storage box mounting locations on roof rack
Removed roof rack brackets from U1300L cab roof
Removed hatch translation arm from U1300L cab
Rough cleaned U1300L cab roof
Cut down height of roof rack brackets by 2 1/2″
Removed unneeded steel from roof rack
Removed paint from roof rack for weld prep
Milled adjustment slots in roof rack brackets
Enlarged bolt holes from 5/16″ to 3/8″ in roof rack brackets
Fabricated roof rack support strut bracket
Fabricated tie down loop bracket plates
Fabricated ladder mount plates
Cut steel for storage box support structure
Purchased additional steel and paint for roof rack
Cut steel for bike enclosure cage
Fabricated, tacked, and TIG welded preliminary bike enclosure frame on roof rack
Match drilled cargo boxes to roof rack