Truck Update 4/29/18

  • Removed fenders in preparation to paint subframe
  • Placed habitat floor panel on subframe
  • Match drilled all mounting holes through subframe into habitat floor
  • Made epoxy repair to small delaminated corner of habitat floor
  • Fit checked exhaust tubing downstream of muffler
  • Removed habitat floor panel from subframe
  • Finish welded exhaust and muffler
  • Continued subframe paint prep
  • Weld prepped subframe for spacer washers
  • Drilled all subframe to habitat bolt holes in frame rails
  • Welded spacer washers into place
  • Prepped and primed subframe
  • Received ignition key blanks
  • Painted subframe gloss black
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Truck Update 4/22/18

  • Final installed cab inner passthrough frame
  • Ordered fender mount hardware
  • Disposed of old passenger bench seat
  • Cut square spacer washers for mid section of subframe under floor
  • Drilled oversized holes in spacer washers
  • Painted kitchen cabinet / pantry gloss white
  • Measured dimensions to make rock shield for top of rear fenders
  • Started laying out new position for muffler assembly
  • Started kitting muffler assembly parts
  • Ordered SBU OEM ignition key blanks from Expedition Imports
  • Welded muffler in new position
  • Removed aft under bed box mounts and jerry can mount in preparation for subframe painting
  • Fabricated exhaust and muffler mount brackets
  • Fabricated and match drilled rock shields for top of rear fenders
  • Welded on muffler bracket and bolted muffler mount bracket to old spare tire mount holes
  • Painted muffler mount
  • Removed driver side under bed storage mount in preparation for subframe painting

Truck Update 4/15/18

  • Received jerry cans
  • Received roof hatch from Tern Overland
  • Received new mechanical suspension cab seats
  • Updated roof hatch installation plan
  • Mocked up fender mounts
  • Mounted rear fenders to subframe
  • Started working to move muffler forward

 

 

Truck Update 4/8/18

  • Purchased steel for spare tire mount, subframe spacers, and back panel hardpoint inserts
  • Prepped, primed, and painted back wall of cab
  • Received drills and taps for subframe
  • Painted cab inner passthrough frame
  • Seam sealed all cab passthrough welds usingΒ Eastwood seam sealer
  • Applied second coat of paint on cab inner passthrough frame
  • Drilled 52 new 1/8″ diameter pilot holes in subframe
  • Final painted back wall of cab
  • Rearranged truck part storage area
  • Installed rear cab ceiling trim
  • Reinstalled rubber edge cover on back wall of cab
  • Removed cab headliner and inspected condition
  • Wiped down cab interior
  • Removed tail light brackets
  • Retorqued bolts that hold subframe to truck chassis (5 were so loose they could rotated by hand)
  • Moved tail lights aft to accommodate storage boxes
  • Relocated rear gladhands
  • Preliminary mounting of aft underbed storage
  • Prepped and painted back portion of truck frame

Truck Update 4/1/18

  • Started welding passthrough frame to cab
  • Received pintal clamp bolt
  • Received acoustic foam
  • Received roof rack cargo boxes
  • Received aluminum trim for passthrough cab interior
  • Finished passthrough structural welding on exterior of cab
  • Ordered jerry cans
  • Ordered seats for cab
  • Marked subframe to hab floor bolt hole locations on subframe rails
  • Started subframe paint prep
  • Finished passthrough tig welding inside cab
  • Finished structural welding of passthrough frame on cab
  • Removed and disposed of foam from inside roof rack cargo boxes
  • Cleaned shop and recycled scrap material
  • Received bellows from Uni-Grip
  • Sketched out plates to fill cab back windows
  • CAD modeled plates to fill cab back windows
  • A friend was nice enough to plasma cut the plates to fill cab back windows: AeroDesign
  • Another friend gave us some Lord 7545 adhesive to try on the bellows: Monolith Aeroworks
  • Applied second coat of paint to habitat passthrough frame
  • Cut aluminum for cab passthrough trim
  • Drilled and tapped mounting holes for cab passthrough trim in cab side steel passthrough frame
  • Machined aluminum spacer for rear pintal shear bolt
  • Trimmed passthrough door
  • Rounded corners of cab side steel passthrough frame
  • Purchased abrasive disc for removing scale from subframe
  • Purchased black silicone to seal removable frame on cab passthrough
  • Continued removing scale from subframe
  • Drilled and tapped holes in cab passthrough frame for removable forward passthrough frame
  • Tack welded plates over old window openings
  • Started touch up paint on back of cab

Truck Update 3/25/18

  • Received kitchen cabinet and locks
  • Received and fit checked 2 1/2″ rear pintal
  • Began truck cab passthrough cutout planning
  • Measured roof rack
  • Researched roof rack cargo box options
  • Started stripping down kitchen cabinet for repaint
  • Started laying out passthrough door
  • Purchased low profile deadbolt lock for passthrough door
  • Cut aluminum for the passthrough door edging
  • Ordered cargo boxes for roof rack
  • Started laying out passthrough door panel
  • Removed unneeded material from inside cab back wall
  • Removed old insulation from cab roof hatch (23 7/8″ diameter)
  • Removed rear cab windows
  • Marked passthrough cut out in back of cab
  • Laminated plywood for passthrough door panel
  • Trimmed down height of kitchen cabinet
  • Marked trim line on and trimmed forward passthrough frame
  • Cut passthrough opening in back of cab
  • Fit checked forward passthrough frame opening
  • Removed passenger seat and unneeded sheet metal
  • Removed rear pintal (42 pound assembly)
  • Bonded aluminum facesheets to passthrough door panel
  • Purchased masonite for new roof hatch insulation mount
  • Started looking for new cab seats
  • Ordered insulation/sound deadening for cab rear wall and roof hatch
  • Started tack welding passthrough frame to cab

Truck Update 3/18/18

One of the main reasons that we decided to make a new habitat for our truck was that we really wanted to incorporate a passthrough into the cab of the truck from the living area. Honestly, we’ve been a little overwhelmed by the logistics of designing and building a passthrough for a while. We figured that now would be the best time to finish the passthrough details before we start assembling the habitat box.

Wabi-Sabi Expedition Truck Passthrough Exploded View
Wabi-Sabi Expedition Truck Passthrough Exploded View

We designed our passthrough to have a frame assembly on the cab side and a frame assembly with door opening into the habitat side. The frames are connected with a water tight EPDM rubber bellows / accordion seal. The cab side assembly is made of 3 steel frames and can be disassembled to disconnect the bellows from the cab if future engine or transmission work requires that the cab be tipped up. The primary cab side frame is welded to the back of the cab.

The habitat side frame is made of 2 steel frames and 1 aluminum frame. The aluminum frame incorporates the door hinge and lock strike plate. The door opens inwards into the shower/bathroom/entry area of the habitat. The door is made from a 1 1/2″ thick insulated RV door panel. The hab side steel frame is bonded to the forward wall of the habitat prior to habitat box assembly.


  • Talked with vendors about passthrough bellows material
  • Finished design of passthrough
  • Cut steel for passthrough frames
  • Cut aluminum RV door frame extrusion material for passthrough door frame
  • Welded habitat and cab side steel pasthrough frame
  • Milled slots for passthrough door hinges in aluminum frame
  • Milled steel corner fillets for bellows connection
  • Welded and finished fillets
  • Ordered passthrough bellows material (ED-5389 from Uni-Grip)
  • Primed and painted habitat exterior passthrough frame

Aluminum Passthrough Frame Assembly

Steel Passthrough Frame Assemblies