Truck Update 4/28/19

Our list of truck work from this past week seemed small to us when we typed it up. There has been a lot going on getting ready for our upcoming trip(s). It is impressive how all the small details take time (getting new keys made, mail forwarding considerations, doctor’s appointments, weeding the yard, insurance updates, etc.). We are planning to do several local test trips to make sure everything is working well, and we were able to do the first test trip this week. It went really well and we identified some changes that we wanted to make for small item storage and provisioning.

Also this week, Yvonne tested out her sewing machine on the inverter. Long story short, her sewing machine didn’t like inverter power and we ended up trying 4 different inverters and 4 different sewing machines. It turns out that some sewing machines are just incredibly picky about power quality, even from a high quality, high capacity pure sine wave inverter. The good news is that we now have a nice Victron pure sine wave inverter and Yvonne has a new “travel” sewing machine that is perfectly happy running off of the Victron inverter. All good news as we near the home stretch of preparations.

  • Took truck on short road trip
  • Inspected truck after trip
    • No leaks, everything looked good
  • Packed under subframe storage boxes
  • Started designing bathroom door
  • Purchased spare fluids for truck
  • Installed new Victron inverter
  • Installed cargo tiedown straps in underbed storage area
  • Started testing sewing machine ergonomics and function
  • Started fabricating bathroom door
  • Finished layout of bathroom door
  • Added pressure relief valve to electric air compressor manifold
  • Lots of trip preparation and logistics planning/organizing
  • Final bonded bathroom door
  • First test trip
  • Laid out all mounting holes on door
  • Applied first coat of paint on door
  • Purchased and installed additional containers for provisioning and organization
  • Moved in clothing
  • Received National Parks pass
  • Cut and urethane sealed oak bathroom door trim
  • Final bonded and assembled bathroom door
  • Installed bathroom door with mirror, waste basket, door handle, closing spring and towel bars

Truck Update 4/21/19

  • Started trip route planning
  • Replaced cabinet hinge pins with small stainless steel bolts and lock nuts
  • Added foam shock cushion to air heater fuel pump mount
  • Added footman’s loops and Velcro straps to secure kitchen cabinet doors
  • Modified/improved engine pre-heater switch mounting in truck cab
  • Turned off axle fording air supply (turned off air regulator)
  • Researched:
    • Other locking fuel tank cap options
    • Air heater ducting insulation
    • Speedometer upgrade options
    • Entry ladder modifications and storing options
    • Electric air compressor wiring modification
    • Engine pre-heater use procedure
  • Bonded and cut foam for Fantastic Vent plug
  • Fabricated pour spout for gallon alcohol cans (for stove fuel)
  • Organized spare parts, extra material, and provisioning
  • Researched electronic maps for route planning
  • Received 2019 Milepost Alaska trip planning book
  • Corresponded with electronic speedometer company
  • Ordered programmable electronic speedometer and sending unit
  • Filled, pressurized, and tested fresh water system
  • Filled and test drained gray water tank system
  • Rewired inside of ARB air compressor
  • Ordered and received material for new speedometer bezel
  • Ordered, received, and installed food grade rubber hose for faucet to sink
  • Received and installed new locking fuel cap
  • Purchase pneumatic components for air compressor installation
  • Purchased hose to drain gray water tank
  • Received heater duct insulation
  • Installed heater duct insulation
  • Fabricated rubber compressor mount pad
  • Installed electric air compressor
  • Plumbed air compressor into truck pneumatic system
  • Started routing air compressor wiring
  • Started laying out new folding ladder design
  • Ordered and received components for auxiliary air take-off system
  • Purchased wheels for new folding ladder base
  • Removed and cleaned section of forward gladhand stainless steel line from truck pneumatic system
  • Added regulated air take-off from high pressure side of truck pneumatic system
  • Removed old speedometer and speedometer calibration gearbox from transmission
  • Cleaned up speedometer calibration gearbox
  • Cut up (newly purchased) folding ladder to make parts for new folding habitat ladder
  • Machined new Delrin bezel for fitting new speedometer in old dash panel hole
  • Started bolting new habitat ladder together
  • Fabricated compression plugs for inside tubes of new ladder assembly
  • Finished wiring electric air compressor
  • Tested electric air compressor and filled truck tanks with engine turned off
  • Started fabricating ladder wheel mounts
  • Received new programmable electronic speedometer
  • Wired lights for new speedometer
  • Fabricated wiring harness for new speedometer
  • Fabricated steel upper mounting tabs for new ladder
  • Modified existing habitat ladder mount to accommodate old and new ladders
  • Re-installed ladder mount on habitat sub-frame
  • TIG welded new ladder mounting bar assembly
  • Match drilled pit-pin holes in new ladder mounting bar assembly
  • Sand blasted and painted new ladder mounting bar assembly
  • Wired and installed speedometer
  • Finished fabricating ladder wheel mounts
  • Sewed cloth cover for Fantastic vent fan plug
  • Received hall effect sending unit for speedometer
  • Sewed drawstring bag for portable propane stove regulator
  • Sewed drawstring bag for portable propane stove
  • Started designing transmission mount for speedometer sending unit
  • Started planning local test trips
  • Started populating truck with provisioning goods
  • Finished fabricating new folding entry ladder (new folding ladder also doubles as a step ladder)
  • Added footman’s loops under bed for securing cargo
  • Tested stowing and setting up sewing machine and OLFA cutting mat
  • Tested invertors and decided to purchase pure sine wave invertor
  • Tested hall effect sensor proximity range
  • Fabricated hall effect sensor mount for speedometer sending unit
  • Bench assembled and tested hall effect sensor assembly for speedometer
  • Installed hall effect sensor sending unit assembly for speedometer
  • Opened up padlock hole for securing spare tire
  • Designed bathroom door
  • Made bond test sample for bathroom door assembly
  • Working toward making final orders to prepare for departure
  • Calibrated speedometer using GPS and radar speed indicator
  • Purchased bathroom door material

Truck Update 4/14/19

  • Added additional heater duct in kitchen wall
  • Tested heater configuration
  • Increased max regulated engine speed from 2600 to 2750 rpm
  • Advanced engine injection timing by 2 degrees
  • Increased injection fuel delivery to ~170 hp setting
  • Tested driving performance after upgrades: noticeable improvement in hill climb / acceleration
  • Purchased tools and materials
  • Applied Wabi-Sabi Overland vinyl decals to habitat and truck
  • Drilled holes in water Jerry cans
  • Installed machined barb bulkhead fittings in water Jerry cans
  • Leak checked water Jerry cans
  • Stowed water Jerry cans in habitat
  • Received:
    • Front portal tank upgrades
    • Drive train boots
    • Portal axle fluid
  • Drove truck to heat up fluids
  • Drained transmission for 2nd fluid change
  • Drained front portal hubs
  • Removed front portal vents
  • Test fit new front portal reservoirs
  • Purchased:
    • Copper crush washers
    • Permatex for drive shaft boot install
  • Started making hardware kit for portal tank upgrade
  • Drilled holes in portal tank caps
  • Machined portal tank dipstick pins
  • Machined portal tank vent return tubes
  • Welded dipsticks
  • Welded vent return tubes
  • Turned down cap screws for inner most portal tank cover holes
  • Installed new front portal tanks
  • Plumbed front portal vents
  • Filled front portal vents
  • Drained residual fluid out of transmission
  • Sealed and installed transmission drain plugs
  • Removed old drive shaft boots
  • Prepped and installed new drive shaft boots
  • Refilled transmission 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