Build Log – Page 7 – Wabi-sabi Overland

Truck Update 7/29/18

Posted on July 29, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

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

Assembled Raskog Interior Cabinets

Frosted Cabinet Glass Using Window Film

Assembled Kitchen Locker

Paint prepped roof rack storage bins

Painted Roof Rack Storage Bins

Truck Update 7/22/18

Posted on July 22, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

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

Added Side and Rear Colored Reflectors

Fit Checked Solar Panels on Roof

Wired Forward Marker Lights

Electrically Tested End to End Wiring of Forward Marker Lights

Electrically Tested End to End Wiring of Rear Marker Lights

Electrically Tested End to End Wiring of Over Bed Lights

Electrically Tested End to End Wiring of Roof Hatch Lights

Electrically Tested End to End Wiring of Roof Hatch Motor

Replaced Reflectors on Sides of Cab

Inspected Fuel Injection Pump Governor

Prepped Cabinet Doors

Painted Cabinet Doors

Prepped Cabinet Sides

Painted Cabinet Sides and Door Pulls

Painting Cabinet Striker Plates

Checked Tachometer Using Manual Strobotac

Strobotac

Painted Cabinet Backs

Painted Cabinet Shelves

Painted Cabinet Tops and Bottoms

Fabricated All Aluminum Angle Mounting Brackets for Solar Panels

Attached Mounting Brackets to Solar Panels Using 3M VHB and Aluminum Pop Rivets

Prepping to Install Solar Panels

Preparing to Install Solar Panels

Bonded Solar Panels to Roof of Habitat

Truck Update 7/15/18

Posted on July 15, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

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

Organized Electrical Supplies

Wired Marker Lights on Rear Frame

Replaced 12V Marker Lights with 24V LED Bulbs

Tested Marker Lights

Bonded and Installed Rear Frame

Installed Ladder and Hoist Side Strut on Rear Frame

Final Wired Rear Marker Lights

Sealed Side Panel to Extrusion Joints with Korapop 225

Received BattleBorn Batteries from Sunsense Solar

Fabricated Rain Guard for Habitat Side Passthrough

Fabricated Forward Upper Marker Light Rail

Replaced and Operationally Checked Forward Marker Light Bulbs with 24V LEDs

Fabricated Forward Upper Marker Light Rail

Placed Reflective Tape Around Upper Corners of Rear Panel

Fit Checking Rain Guard

Drilled and Tapped Rain Guard Mounting Holes

Bonded and Installed Rain Guard

Fit Checking Forward Marker Light Rail

Bonded Forward Upper Marker Light Rail

Truck Update 7/8/18

Posted on July 8, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

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

Fixturing and Welding Upper Driver Side Grab Handle

Machined Marker Light Wire Guide Mount Tabs

Final Match Drilled Ladder to Rear Mount Frame

Fitting and Welding Lower Sand Ladder Stud

Fitting and Welding Upper Sand Ladder Stud

Sandblasted Sand Ladder Hold Down Nuts

Painted Sand Ladder Hold Down Nuts

Sand Ladder Hold Down Nut

Machined Nylon Spacer Sleeves for Sand Ladder Mount

Machined Sand Ladder Spacer Retainer Nut

Machined Nylon Spacer Sleeves for Sand Ladder Mount

Machined Aluminum Sand Ladder Retaining Caps

Test Fitting Sand Ladder Mount and Lock Assembly

Machined Tire Locking Plate

Painted Tire Locking Plate

Machining, Fitting, and Welding Steel Solar Wire Passthrough Tube

Received 4-Gauge Welding Wire for Solar Panels

Received Aluminum for Mounting

Received ARB Awning

Received Flooring Samples

Primed Rear Frame

Painted Rear Frame

Started Prepping Interior Cabinets for Painting

Started Fabricating Forward Marker Light Mount

Prepping to Final Seal Rear Habitat Wall to Extrusion Joints with Korapop 225

Final Sealed Rear Habitat Wall to Extrusion Joints with Korapop 225

Prep Work for Habitat Door Installation

Prep Work for Installing Habitat Door

Tern Overland Euro Door Mounting Clip

Removing Korapop 225 Squeeze-Out from Door Installation

Installed Habitat Door

Truck Update 7/1/18

Posted on July 1, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

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

Turning Tire Mount Plate Centering Spacer

Tire Mount Plate Centering Spacer

Milling Outer Round Contour of Spare Tire Mount Plate

Tire Mount Plate Finish Milled

Drilling Lug Holes in Tire Mount Plate

Milling Side Gussets for Spare Tire Mount Plate

Tire Mount Plate Side Gussets

Removing Plating from Spare Tire Mount Lug Before Welding

Fixturing Tire Mount Plate

Welded Tire Mount Plate Assembly

Fit Check Tire Mount Plate

Fixtured and Clecoed Corner Caps

Corner Cap and Korapop 225

Scraping Squeeze Out on Corner Cap

Final Bonded Corner Cap

Size 194 LED Marker Light 12_24 V Bulb

Grote Amber Marker Lights

Function Checking LED Marker Light Bulb

LED Fog Lights

100W Monocrystalline Solar Panel

Aircraft Microstop

Countersinking Cleco Holes with Aircraft Microstop

Countersunk Cleco Hole

Sealing Countersunk Hole Using Korapop 225

All Corner Caps Finished

Drilled Hole for Airhead Composting Toilet Fan

Sealing Interior Habitat Joints Using Korapop 225

Sealed Passthrough Frame Using Korapop 225

Notching Tire Mount Structure

Fixturing Plate Assembly Into Rear Frame

Tack Welded Tire Mount Assembly Into Rear Frame

Cutting Tire Mount Cross Member

Chamfering Tire Mount Cross Member

Fixturing Tire Mount Cross Member

Truck Update 6/24/18

Posted on June 24, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

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

Crimped and Terminated Wires in Rear Lower Passenger Corner

Started Evaluating Roof Solar Panel Configurations

Selected Solar Panels

Cutting Acoustic Foam to Secure Wires in Extrusion

Securing Wires in Extrusion with Acoustic Foam

Spliced Exterior Wiring to Go Through Gland Nuts

Wire and Gland Nut Fit Check

Created Cut Template for Interior Over Bed Lighting

Wired Over Bed Lighting

Installed Over Bed Lighting

Test Fit Cabinet in Several Desired Interior Locations

Completed Preliminary Welding of Spare Tire Mount Plate

Painted Tire Hoist Side Strut

Milled Mounting Flat on Upper Sand Ladder Mount Bolt

Dry Installed Gland Nuts

Fixtured and Clecoed Upper Corner Caps

Truck Update 6/17/18

Posted on June 17, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

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

Machined Sand Ladder Hold Down Nut Components

Machined Sand Ladder Mount Studs

Machined Sand Ladder Hold Down Nut Components

Taped Out Floor Plan and Cabinet Positions

Drilled Mounting Clearance Holes in Tire Mount Frame

Installed Over Bed Windows

Installed Over Counter Windows

Drilled and Tapped Mounting Holes in Rear Panel Hardpoints for Mounting Frame

Bonded Access Hatches

Clipped Access Hatches

Installed Access Hatches

Installed Weather Stripping on Access Hatches

Installed Fan-tastic Vent

Wired and Installed Fan-tastic Vent

Installed Fan-tastic Vent

Wired and Installed Fan-tastic Vent

Installed Fan-tastic Vent

Measured Roof Area for Solar Panels

Machined Marker Light Brackets for Rear Mount Frame

Prepped for Roof Hatch Install

Bonded Roof Hatch

Clipped Roof Hatch

Wired Roof Hatch

Finish Installed Roof Hatch

Truck Update 6/10/18

Posted on June 10, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

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

Chamfered Edages of Rear Wall Panel

Prepping Steel Hardpoints for Rear Panel

Prepped for Rear Wall Steel Hardpoint Bond

Steel Hardpoint Rear Wall Bond

Drilling and Tapping Mid Span Clamp Up Bolts for Rear Wall Hardpoint Bond

Steel Hardpoint Rear Wall Bond Complete

Tire Mount Ladder Brackets

Tack Welded Tire Mount Ladder Brackets

Test Fit Tire Boom Hoist Side Strut

Fit Checking Rear Extrusions

Positioned Tire Mount on Rear Panel

Match Drilled Pilot Holes for Tire Mount on Rear Panel

Installed and Wire Wrapped Rear Panel Wiring

Installed Rear Panel Wiring

Bonded Lower Extrusion to Rear Panel

Ran Wiring on Back Edge of Roof Panel

Bonded Driver Side Vertical Extrusion on Rear Panel

Final Bonded Rear Panel

Final Bonded Rear Panel – Last Panel Bond!

Removed Clamps from Rear Panel

Habitat Internal View After Panel Bonds Complete

Truck Update 6/3/18

Posted on June 3, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

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

Tire Mount

Steel for Tire Mount

Cutting Steel for Tire Mount Frame

Truing Tire Hoist Component

Tire Mount Frame Layout

Welding Tire Mount Frame

Fit Checked Tire Ladder and Sand Plates on Tire Mount Frame

Milling Tire Hoist Plate

Tire Hoist Plate

Removing Unneeded Material from Tire Hoist

Tack Welded Tire Hoist

Fabricating Drill Bit for Wire Runs

Drilling Wire Passthrough

Drilling Wire Passthrough in Extrusion

Trimming Rear Vertical Extrusion

Clearanced Upper Fore-Aft Extrusions

Roof Ready to Lift

Roof Lifted in Place

Bonded Forward Upper Extrusion

Applying Adhesive for Roof Bond (Note Wiring)

Bonded Roof Panel

Truck Update 5/27/18

Posted on May 27, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

Received and fit checked waterjet aluminum adapter plates for roof hatch
Fit checked key blanks in truck
Deburred and paint prepped aluminum roof hatch adapter plates
Masked off bond areas on aluminum roof hatch adapter plates
Primed and painted aluminum roof hatch adapter plates
Disposed of scrap material from subframe
Started laying out wiring diagram
Started detail design of tire mount
Laid roof panel on floor to prepare for edge champher
Ordered habitat wiring
Fit checked fantastic fan in roof panel cutout
Champhered top edges of roof panel
Received habitat wiring order
Cut foam for core between aluminum hatch adapter plates
Prepped and bonded top roof hatch adapter plate
Routed top side of hatch opening
Flipped over roof panel
Champhered lower edges of roof panel
Prepped and bonded lower roof hatch adapter plate
Routed bottom side of hatch opening and removed excess composite panels

We encountered an unforeseen mix-up in the layout of our roof panel when we received the physical roof hatch from Tern Overland. It was a bit of a collaborative miss with everyone involved (us, Total Composites, and Tern Overland). When we originally laid out our roof panel, the orientation of the roof hatch was not obvious and we accidentally assumed that the hinge would be on the narrow side of the hatch like many American hatches. It was a bit of a surprise when we opened the box and read the instructions and found that our opening was rotated 90 degrees in our panel from what it needed to be.

We hadn’t actually specified dimensions of the hatch opening when we supplied the information for the box layout. We just specified the center position of the hatch and said that there needed to be an opening for the supplied roof hatch. We did, however, have a rectangle in the layout drawings that was longer fore-and-aft and narrower side-to-side. We had assumed that any needed details of the hatch layout would be double checked against the requirements of the hatch, but unfortunately, that did not happen.

The bottom line is that we should have requested the full installation instructions for the hatches, windows, and door prior to submitting our box layout for build. Also, it’s best to get instructions directly from manufacturers via email instead of relying on what is on websites as products and details online can change over time.

Overall, we have a pretty good recovery plan. We had 2 aluminum plates water jet cut that bond to the upper and lower surfaces of our habitat roof and act as “adapters” to rotate the orientation of the roof hatch cutout. The plates add minimal weight and actually reinforce the roof around the large roof hatch opening.