Build Log – Page 2 – Wabi-sabi Overland

Truck Update 3/17/19

Posted on March 17, 2019May 4, 2019 by Yvonne @Quilting Jetgirl

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

Drained coolant

Removed old engine pre-heater (120V AC electric)

Removed brackets in engine bay that interfered with pre-heater

Fabricated pre-heater mount brackets

Installed new pre-heater brackets

Lubricated and measured steering box adjustment stud size

Received fuel filters

Machined aluminum hose union

Removed engine water pump outlet hose and removed pre-heater outlet hose

Purchased and trimmed new radiator hoses

Replaced lower radiator hose

Mounted pre-heater and finalized pre-heater plumbing

Purchased Zerex G05 50/50 coolant

Refiled engine with Zerex G05 coolant

Started engine and burped coolant system

Test drove and evaluated fluids

Truck Update 3/10/19

Posted on March 10, 2019May 4, 2019 by Yvonne @Quilting Jetgirl

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

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

Moved truck back to shop

Drained engine oil, transmission fluid, and differential oil

Filled transmission with Redline MT-85 (GL-4)

Drained engine oil, transmission fluid, and differential oil

Filled differentials with Redline 75W-90 (GL-5)

Bled brakes

Torqued lug nuts

Reduced tire pressure to 55psi

Replaced oil filter and filled engine with oil (Rotella 15W-40)

Test rain engine to check for leaks and oil level

Truck Update 3/3/19

Posted on March 3, 2019May 4, 2019 by Yvonne @Quilting Jetgirl

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

Fabricated stainless steel rear wheel shield plates

Bonded on stainless steel over tire rock shields

Fabricated dinette foot rest

Prepped, masked, and bond installed dinette foot rest

Drilled pilot hole for under sink drain

Drilled 1 inch hole for under sink drain and installed drain hose

Drilled hole and installed tube for fresh water vent

Sewed ratchet straps for under subframe box anti-rattle

Tested cold weather performance of habitat using small space heater

Made plywood mounting palette for under sink fresh water pump assembly

Fit checked under sink pump assembly

Painted plywood mounting palette for under sink pump assembly

Wired and plumbed final water pump assembly

Truck Update 2/24/19

Posted on February 24, 2019May 4, 2019 by Yvonne @Quilting Jetgirl

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

Fit checked and installed left and right bed decks

Wired and tested bed deck ventilation fans

Installed overhead storage bins

Installed stove alcohol cans

Fabricated stand offs for water pump mount

Installed water pump mount standoffs under sink

Installed Froli star bed springs

Installed mattress

Checked ergonomics of bed height

Test fit custom quilt

Measured, fabricated, and painted wire chase cover for over head board

Installed wire chase cover

Cut and painted support for aft dinette seat back

Installed dinette seat backs

Measured and cut plywood for seat backs

Bonded and trimmed 1-inch foam on seat back panels

Upholstered dinette seat backs

Installed dinette seat backs

Installed support for aft dinette seat back

Installed dinette seat backs

Cold outside and cozy inside

Truck Update 2/17/19

Posted on February 17, 2019May 4, 2019 by Yvonne @Quilting Jetgirl

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

Prewired GFCI breakers on bench

Made mounting brackets for inverters

Installed inverters and GFCI breakers

Finished all heater duct work

Cleaned underbed area

Drilled mounting holes in under bed storage bins

Installed underbed storage bins

Carpeted exposed surfaces in underbed cargo area

Fabricated cargo net top mounting angle

Installed cargo net mounting angle

Installed cargo net

Test fit driver side bed deck

Picked location for overhead storage bins on bottom of bed deck

Mounted overhead storage bins to underside of drive side bed deck

Installed electrical distribution panel polycarbonate shield

Under bed area finished and ready for bed deck

It’s nice to have the truck out in the open for a while

Satisfying to see interior progress

Truck Update 2/10/19

Posted on February 10, 2019May 4, 2019 by Yvonne @Quilting Jetgirl

Tested solar charging system under load
Drilled bolt access holes in driver side under subframe storage box heat shield
Made heater duct distribution box
Cleaned under subframe storage boxes
Remounted rear license plate
Ran heater fuel line and heater pump wiring forward to fuel tank area
Drilled and painted vent holes in water tank area
Touched up paint in habitat
Painted heater duct box
Sealed vent holes in under subframe storage boxes with aluminum plates
Silicone sealed under subframe storage boxes
Added weather stripping to lids of under subframe storage boxes
Installed under subframe storage boxes
Bonded and screwed heater duct flanges to heater distribution box
Bonded heater distribution box into habitat
Measured driver side bed deck vent hole positions
Measured inverter area
Started laying out inverter and GFCI breakers
Wired and installed composting toilet vent fan
Installed composting toilet
Made new bug screen for toilet intake (oops, I broke the first one)
Drilled additional vent holes in driver side bed deck

Drilled bolt access holes in driver side under subframe storage box heat shield

Cleaned under subframe storage boxes

Sealed vent holes in under subframe storage boxes with aluminum plates

Added weather stripping to lids of under subframe storage boxes

Installed under subframe storage boxes

Made heater duct distribution box

Painted heater duct box

Bonded and screwed heater duct flanges to heater distribution box

Bonded heater distribution box into habitat

Drilled additional vent holes in driver side bed deck

Drilled and painted vent holes in water tank area

Installed composting toilet

Made new bug screen for toilet intake

Truck Update 2/6/19

Posted on February 6, 2019May 4, 2019 by Yvonne @Quilting Jetgirl

Installed white rubber seal strip around entry door
Modified entry door screen clips
Fabricated insect seal between screen and wall
Installed screen mounting clips with VHB
Installed screen door
Fabricated additional battery cables
Installed battery cutoff switches
Installed batteries
Final wired solar charge controller
Final wired battery assembly
Set battery monitor for lithium batteries
Tested overall battery system using battery power
Cleaned and organized shop space
Organized truck materials
Installed velcro on bed deck contact surfaces
Drilled heater mounting holes
Dry fit composting toilet
Bench assembled heater
Installed heater in habitat
Fabricated heat shield for heater on underside of habitat
Bonded and screwed in heat shield
Installed heater insulation
Installed both under subframe storage box mounts and boxes
Started preliminary layout of heater ducting
Wired heater
Started running heater ducting

Installed white rubber seal strip around entry door

Modified entry door screen clips

Fabricated insect seal between screen and wall

Installed screen door

Fabricated additional battery cables

Installed batteries and battery cutoff switches

Drilled heater mounting holes

Bench assembled heater

Installed heater in habitat

Fabricated and installed heat shield for heater on underside of habitat

Installed both under subframe storage box mounts and boxes

Installed velcro on bed deck contact surfaces

Wired heater

Started running heater ducting

Table cushions and flooring

Tested overall battery system using battery power

Truck Update 2/3/19

Posted on February 3, 2019May 4, 2019 by Yvonne @Quilting Jetgirl

Designed under subframe storage box lock plates
Fabricated under subframe storage box lock plates
Welded lock plates to under subframe storage box mounts
Welded anti-rattle ratchet strap tabs to under subframe storage box mounts
Welded steel heater exhaust heat shield to driver side under subframe storage box mount
Primed under subframe storage box mounts
Removed protective film from windows on entry door
Cut, fit, and installed shower curtain track over shower
Drilled holes in entry ladder mount for padlock
Prepared under sink area for fresh water tank installation
Fit checked water jerry can under sink (fits great!)
Seam sealed and painted under subframe storage box mounts
Started installation of marmoleum flooring
Received overhead storage bins (for under bed)
Removed right side driver’s arm rest
Finished installing marmoleum flooring
Fit checked screen door
Purchased screen door installation hardware and other hardware store supplies
Router kerfed underside of dinette table
Mounted table leg socket to underside of table
Cut table leg to length
Fit checked dinette table
Mounted table leg socket to floor of habitat
Bonded in dinette table