Truck Update 3/17/19

  • 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
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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 11/7/18

  • Covered foam rubber passthrough plug
  • Reduced length of driver side right arm rest to clear gear shift
  • Test fit passthrough plug
  • Started troubleshooting cab speaker issue
  • Fastened carpet along door edge (both sides)
  • Secured loose edge on driver side carpeted door panel
  • Researched fuel injection pump governor adjustment
  • Researched and ordered candidate cab speakers
  • Sent inquires about:
    • Air dryer desiccant cartridge
    • Forward and rear drive shaft boots
    • Injection pump hand primer pump
    • Locking gas cap
    • Fuel injection pump adjustment
  • Designed basic layout of under kitchen counter support
  • Cut wood for under kitchen counter support
  • Assembled, glued, and screwed under kitchen counter support
  • Started making supports for under counter gray water tank and fuel alcohol storage
  • Bonded tank standoff strips to kitchen cabinet rear panel
  • Started making support base for kitchen pantry
  • Started making storage locations for large kitchen items
  • Made and installed cast iron frying pan mount plate
  • Purchased kitchen cabinet material
  • Worked on build sequence and scheduling
  • Bonded and cut plywood base for kitchen pantry
  • Applied thread locker to kitchen pantry assembly bolts
  • Added 2 additional slides to slide out / cutting board
  • Started bed frame and kitchen wall design
  • Ordered rubber drive shaft boots, fuel pump primer, and air dryer cartridge (Eurotruck Importers)
  • Inquired about charge controller and battery maintenance from Battle Born
  • Started picking preliminary dates for summer 2019 Canada / Alaska trip
  • Double checked internal dimensions and squareness of habitat
  • Selected plywood thickness for walls and bed structure
  • Fabricated corral for fuel alcohol storage
  • Received water pump

We are starting to transition from truck/cab work to internal habitat work. We have been doing a lot of schedule and task planning behind the scenes. We have a big list of tasks required to finish the truck. We have the list divided into several categories based on type of work and with a goal of starting test trips in the next 2 months. Some things can wait until spring, so we are concentrating on getting the truck ready for basic uses. A lot of the upcoming work is centered around designing small details of the habitat interior.

Truck Update: 11/4/18

Thanks for all the help this week, MK and FR!

  • Masked off countertop
  • Paint prepped under counter riser
  • Painted under counter riser white
  • Masked off under counter riser
  • Urethaned countertop
  • Organized and cleaned truck work area
  • Installed slides and drawers in kitchen cabinet
  • Installed all drawer screws with epoxy
  • Applied sound deadening mat to underside of hood (Noico)
  • Templated and applied sound deadening mat to cab floor and firewall (Noico)
  • Templated and installed carpet on cab floor and firewall
  • Installed rubber mat over carpet
  • Final installed sound deadening floor mat
  • Final installed cab seats
  • Installed arm rests on cab seats
  • Started wiring cab stereo speakers
  • Test drove truck for first time in a year

The main activity this week was finishing out the interior of the cab and doing as much sound deadening improvements as we could. We covered the entire floor, firewall, transmission hump, and engine cover with 80 mil Noico butyl sound deadening mat.  Depending on the area of the floor, we put anywhere from 1 to 3 layers of the Noico mat. It went on quite well and was a nice material to work with.

Over the Noico sound deadening mat, we covered the back part of the floor and the transmission hump with a thick molded rubber sound deadening mat that we sourced from Atkinson Vos. The normal sound deadening kit from Atkinson Vos can be up to a year lead time, but we were able to buy a portion of it and have it shipped to us right away. The mat is quite nice but it did require a lot of fitting and cutting. All the other areas with Noico mat were covered with indoor/outdoor carpet. We then placed rubber mats on top of the carpet in the foot pans of the floor. With all the other felt and melamine foams that we added, the cab is very noticeably quieter.

With the cab assembled and both seats final installed, we were able to drive the truck together for the first time in almost a year. It was really encouraging to see and hear what an improvement all of our modifications and fixes have made.  We only got the truck up to about 40 miles and hour on the small roads near the shop, but it looks like the tires are pretty nicely balanced, the truck shifts a lot better, the rear view camera is really helpful, the seats are quite comfortable, and all the sound deadening work has made a really huge improvement. We were able to easily carry on a conversation while driving. Overall, it was a very encouraging experience to get the truck back out on the road.

Truck Update: 10/31/18

  • Fit checked sound deadening floor mats and marked additional trim area
  • Removed driver side door window track
  • Measured and laid out design for passthrough insulating plug
  • Marked areas to apply sound deadening mat on cab floor
  • Straightened driver side door window track
  • Trimmed sound deadening floor mat
  • Final fit checked sound deadening floor mat
  • Applied sound deadening mat to firewall and sheet metal areas behind glove box
  • Reinstalled glove box assembly
  • Bonded felt to top of dash
  • Reinstalled engine access cover
  • Cleaned and bond prepped interior of doors
  • Applied sound deadening mat to interior surfaces of doors
  • Reinstalled driver side window track
  • Lubricated window opening mechanism in both doors
  • Cleaned out cab floor cavity between seats
  • Silicone sealed drain hole in cab floor cavity
  • Measured cab floor cavity and passthrough opening for acoustic foam
  • Bond tested foam rubber samples using superglue and 3M 90 spray
  • Bonded indoor/outdoor carpet to cab door panels
  • Trimmed carpet to edge of cab door panels
  • Bonded foam rubber for passthrough acoustic plug
  • Cut foam rubber to fill cab floor cavity
  • Researched water pump options
  • Researched hot water storage options
  • Cut and fit checked foam rubber for passthrough acoustic plug
  • Applied sound deadening mat to cab floor cavity cover
  • Lubricated cab window mechanism, door latches and locks
  • Sealed doors with plastic and double sided tape
  • Reinstalled carpeted door panels
  • Applied sound deadening mat to cab floor cavity
  • Installed foam rubber and cover on cab floor cavity
  • Received soft close ball bearing drawer slides for kitchen drawers
  • Filled imperfections in kitchen countertop
  • Sanded kitchen countertop and riser
  • Assembled, bonded, and screwed kitchen drawers
  • Reinforced kitchen drawers with 1/2″ poplar strips
  • Bonded and screwed on kitchen drawer faces

Truck Update: 10/28/18

  • Designed under countertop riser
  • Cut, fitted, and sanded wood for under countertop riser
  • Received candidate sink gray water tank and kitchen goods tie down options
  • Assembled, bonded, and screwed under countertop riser
  • Cut 5mm plywood for back of kitchen cabinet
  • Cut 3/4″ plywood for under stove support
  • Final assembled under counter riser
  • Designed under counter slide out/cutting board
  • Fabricated structure for under counter slide out/cutting board
  • Created outlet cutout in face of cabinet
  • Routed edge of scrap oak
  • Bonded scrap oak for slide out/cutting board
  • Test fit sink, faucet, and stove
  • Test fit sound deadening floor mat
  • Trimmed and marked additional areas to trim in sound deadening floor mat
  • Cut away unneeded steel brackets on cab floor
  • Made templates for wool felt for:
    • Engine access door
    • Glove box
    • Top of dash
  • Purchased cabinet material
  • Received battery cables
  • Trimmed and cut away extra sound deadening floor mat material
  • Unclamped bonded oak and cut to slide out/cutting board final size
  • Disposed of old driver side seat
  • Continued fit checking components to refine interior layout
  • Dry assembled slide out/cutting board
  • Painted and urethaned slide out/cutting board
  • Started design work on kitchen cabinet to floor frame
  • Cut and trimmed felt insulation for cab
  • Fit checked sound deadening floor mats and marked additional areas to trim
  • Fit checked felt
  • Removed cab door panels
  • Removed glove box
  • Removed rear engine access cover
  • Purchased cab insulation and kitchen cabinet supplies
  • Covered ash tray indentation in engine access cover
  • Final assembled slide out/cutting board
  • Filled wood grain cracks in edge of countertop
  • Opened up kitchen outlet cutout
  • Researched GFCI wiring for invertors
  • Painted engine access cover texture black
  • Trimmed away marked sound deadening floor mat material
  • Disassembled and cleaned glove box
  • Bonded felt to engine access cover and glove box door
  • Drilled mounting holes and test mounted alcohol stove
  • Applied sound deadening mat to back side of glove box

Truck Update: 10/24/18

  • Ordered habitat and winch battery cables from Battery Cables USA
  • Ordered Tyco W58 circuit breakers and heavy duty 12V switches for habitat breaker panel from Aircraft Spruce
  • Painted seat mounts
  • Machined new bushings, pins, and roller for driver side suspension seat
  • Purchased material to start kitchen cabinet build
  • Started building lower kitchen cabinet
    • We are trying to make quick progress on our cabinet woodworking while making sure that it will be durable enough for many years of travel and use. We are building our kitchen cabinets using some store bought hardwood cabinet components. We are upgrading and making custom wood parts where appropriate. All of the joints are bonded with Titebond II or Korapop 225 and then screwed together. The screws are bonded in place using 5-minute epoxy to prevent them from rattling out over time. We have found that modular hardwood kitchen items are really great for base woodworking to build off of.
  • Inspected power steering pump adjust-ability
  • Removed entire shift linkage to fix unacceptable shift slop
  • Cleaned, disassembled, and inspected shift linkage
  • Machined new bushings and pin assembly for shift linkage
  • Purchased red oak for countertop
  • Purchased assorted kitchen cabinet hardware
  • Bonded red oak lumber together for countertop
  • Ordered candidate sink gray water tank and kitchen goods tie down options
  • Reassembled gear shift assembly
  • Installed shift linkage and adjusted gear shift assembly in truck
  • Sealed threaded holes in cab floor using RTV
  • Put reflective tape on front bumper
  • Disassembled, inspected, lubricated, and adjusted throttle linkage assembly
  • Adjusted idle stop
  • Cut countertop to size and sanded surface
  • Purchased kitchen cabinet material
  • Finalized layout of kitchen counter cutouts
  • Trimmed down, sanded, and blended sink flange
  • Cut hole for sink in kitchen countertop
  • Routed and bullnosed sink cutout
  • Drilled plumbing hole for kitchen faucet
  • Routed cutout for stove in kitchen countertop
  • Received breakers and switches