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 4/7/19

  • Received shower plumbing fittings
  • Received entry door grab handle mount hardware
  • Received gray water tank hold down hardware
  • Cleaned and sealed driver side under subframe storage boxes
  • Riveted rubber Jerry can support bumpers
  • Started looking at injection pump adjustment access
  • Installed
    • Driver side under subframe mount
    • Under subframe storage boxes
    • Driver side Jerry cans
    • Gray water tank
  • Plumbed kitchen sink to gray water tank
  • Installed gray water tank vent tube
  • Installed gray water tank vent valve
  • Measured toilet vent fan splash guard area
  • Started laying out shower drain plumbing
  • Purchased additional plumbing parts for shower drain
  • Final installed air heater exhaust muffler
  • Secured air heater intake silencer
  • Ordered steel for rear bumper assembly
  • Recieved entry door grab handle
  • Fabricated toilet vent fan splash guard
  • Cut stainless steel screen for toilet vent fan splash guard
  • Final installed toilet vent fan splash guard
  • Started looking at habitat door hold open catch
  • Installed shower drain plumbing assembly
  • Connected shower drain to gray water tank
  • Fabricated external entry door grab handle mount assembly
  • Installed external entry door grab handle
  • Started looking at ladder storage
  • Started looking at passthrough door hold open catch
  • Located passthorugh door bump stop
  • Started designing forward internal entry door grab handle
  • Bench assembled electric air compressor to truck manifold
  • Received rear bumper material
  • Received tire air gauges
  • Finished fabricating forward internal grab handle components
  • Fabricated passthrough door bump stop
  • Fabricated bracket assembly for entry door hold open catch
  • Installed forward internal grab handle
  • Installed electric air compressor manifold onto truck
  • Installed footman’s loop in passthrough for door open catch
  • Bonded passthrough door bump stop
  • Installed entry door hold open catch bracket and footman’s loop
  • Cut steel for rear bumper tube
  • Tack welded full length of bumper tube
  • Final welded bumper tube joints
  • Cut clamp up tubes for mud flap bolts
  • Welded clamp up tubes into bumper
  • Fit checked bumper tube on truck
  • Primed and painted bumper tube
  • Stenciled fuel tank and Jerry cans
  • Reamed out mud flap bolt holes on bumper tube
  • Prepped weld location for bumper mount
  • Mounted bumper to truck
  • Touched up paint on bumper assembly
  • Cut rubber for mud flaps
  • Cut aluminium for mud flaps
  • Made bolt kit for mounting mud flaps
  • Put reflective tape on bumper
  • Installed mud guards and flaps

Truck Update 3/31/19

  • Removed forward gladhand line
  • Fit checked gray water tank and located sink drain fitting
  • Plumbed fuel line for pre-heater
  • Wired pre-heater and pre-heater pump
  • Test ran pre-heater
  • Ran speaker wire and tested speakers in cab
  • Installed Noico sound deadening mat over driver
  • Wired and tested GPS odometer
  • Started modifying gray water tank
  • Fit checked hose barbs on gray water tank
  • Mounted speakers in cab
  • Tested alternate pre-heater control switch
  • Decided to change pre-heater control to single switch instead of “smart controller”
  • Final wired pre-heater and tested pre-heater
  • Wired 12V compressor relay circuit (for future 24V compressor)
  • Reprogrammed GPS odometer to default to miles
  • Looked at hab entry door grab handle positions
  • Purchased gray water tank internal tubing
  • Sealed firewall passthrough hole
  • Added additional power ground location inside cab
  • Modified gray water barb fittings to better accommodate hose
  • Final assembled gray water tank
  • Labeled gray water tank with stencil
  • Clearanced gray water tank hold down and touched up paint
  • Organized tools
  • Cleaned storage boxes for under subframe on driver side
  • Started looking at under subframe storage locking options
  • Trimmed 12mm stainless air line for electric air compressor to truck interface
  • Cut metal for storage box lock mount
  • Welded lock assembly for under subframe storage boxes
  • Welded two footman’s loops for storage box anti-rattle strap
  • Clearanced back of under subframe storage box mount
  • Enlarged rivet holes for jerry can bumpers on under subframe storage box mount
  • Purchased shower drain tubing
  • Purchased paint for under subframe storage box mount
  • Sewed anti-rattle strap
  • Prepped, seam sealed, primed, and painted under subframe storage box mount

Truck Update 3/24/19

  • Reviewed fuel filter change and fuel bleed procedure
  • Worked on auxiliary systems fuel tank mounting design
  • Refreshed memory on how to:
    • Adjust max governed RPM
    • Advance engine injection timing
    • Increase injection pump fuel delivery
  • Reviewed engine pre-heater controller options
  • Removed engine components to gain access to fuel filters
  • Removed old fuel primer pump
  • Installed new fuel primer pump
  • Replaced both fuel filters
  • Bled fuel system
  • Reassembled removed engine components
  • Ran engine and checked for leaks
  • Tested out variety of way to access engine pump adjustment
  • Inspected air filter (nice and clean)
  • Trimmed interfering material away from gray water tank hold down
  • Prepped and primed gray water tank hold down
  • Seam sealed gray water tank hold down
  • Painted gray water tank hold down
  • Ordered gray water tank fittings
  • Reviewed heater and pre-heater fuel line hardware
  • Reviewed electric air compressor wiring
  • Reviewed pre-heater wiring
  • Reviewed speaker wiring diagram
  • Disconnected winch from truck batteries
  • Purchased small filter for diesel air heater
  • Drilled holes in fuel tank for heater and fuel heater fuel supply
  • Used magnets inside tubing to remove any metal particles from inside tank (it worked really well)
  • Trimmed fuel fitting standpipes to prevent heater from completely draining truck fuel tank
  • Mounted fuel fittings in fuel tank
  • Test ran electric air compressor
  • Installed air heater fuel pump
  • Finished air heater installation and purged air from fuel lines
  • Test ran air heater
  • Disposed of old engine coolant
  • Topped off engine coolant
  • Received gray water tank fittings
  • Test fit jam nut on power steering box (12M-1.5)
  • Extended wire length for speakers
  • Installed filter and fuel pump for engine pre-heater
  • Purchased switch for engine pre-heater
  • Ordered additional air heater ducting and swivel vent
  • Fabricated GPS odometer, compressor, and pre-heater switch bracket dash panel
  • Painted switch bracket dash panel
  • Bench assembled and installed switch bracket dash panel
  • Removed unneeded / redundant passenger seat lap belt
  • Tested out additional heater duct in kitchen (we will likely add more ducting)
  • Cut witness groove in end of power steering adjustment stud (to maintain original reference position)
  • Removed power steering adjustment jam nut and cleaned threads
  • Installed new seal and jam nut on power steering box
  • Adjusted steering slop out of power steering box
  • Test drove truck to check steering play
  • Washed truck

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