Habitat – Page 5 – Wabi-sabi Overland

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 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