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.

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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.Β  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.Β  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

Truck Update: 10/21/18

  • Received sound deadening mat
  • Received audio extension cable
  • Replaced steel clip in cab head liner
  • Measured position of cabinets in habitat
  • Organized truck material
  • Unboxed seats and started mount design
  • Fabricated cabinet mount plates
  • Received bolts, washers, and nuts for cabinet door hinges
  • Ordered felt for dashboard
  • Disposed of shipping packaging for truck parts
  • Started assembly of lower kitchen cabinet
  • Inquired about roof hatch fuse amperage
  • Ordered winch and house battery ANL high current fuses
  • Started creating preliminary habitat electrical system layout
  • Started creating layout for habitat breaker panel
  • Painted lower kitchen cabinet doors white
  • Removed driver’s seat
  • Received LED under cabinet lights
  • Received wool felt for cab sound deadening
  • Researched and selected breaker amperage requirements for all habitat electrical systems
  • Selected switches for power panel
  • Measured cab head height for new seats
  • Started designing seat mounts
  • Test fit mounts for Ikea cabinets
  • Test cooked on alcohol stove
  • Timed water to boil on alcohol stove
  • Researched cab heater control operation
  • Bonded mounting plates to back of bathroom Ikea cabinets
  • Measured mount point locations for seats in floor of cab
  • Designed driver’s side seat mount
  • Fabricated driver’s side seat mount using components from new seat and old seat
  • Received high current ANL fuses
  • Bonded mounting plates to back of bedroom Ikea cabinets
  • Purchased steel for passenger side seat mount
  • Fabricated passenger side seat mount
  • Test fit seat mounts and new seats in cab

Truck Update: 10/14/18

  • Fabricated plates to secure center dash panel
  • Drilled and tapped center dash panel
  • Painted plates to secure center dash panel
  • Researched and selected fuse upgrade for winch wiring
  • Purchased hole saw for mounting deadbolt in passthrough door
  • Started bond prepping passthrough door parts
  • Marked out deadbolt location on passthrough door
  • Finished center dash panel installation
  • Sealed backup camera electrical connectors
  • Replaced backup camera bolts with proper grip
  • Secured air lines and wires on chassis
  • Cleaned and photographed data tags on pneumatic system
  • Cleaned underneath dash on driver side: brake, clutch, etc.
  • Researched air dryer cold climate systems
  • Drilled passthrough door deadbolt lock hole
  • Dry assembled and prepped passthrough door
  • Primed all passthrough door parts with Sika 205 activator
  • Final assembled passthrough door using Korapop 225
  • Masked and RTV sealed cab side passthrough frame
  • Measured for dynamat
  • Researched fusible links for house batteries
  • Cleaned passthrough bellows material
  • Prepped and cleaned passthrough frame
  • Installed passthrough bellows
  • Trimmed excess passthrough bellow material
  • Tested bonding passthrough material (EPDM) with Lord adhesive 7545 – mediocre bond strength
  • Installed passthrough door hinges
  • Trimmed passthrough door for better fit
  • Installed passthrough door
  • Started comparing hab interior structure options
  • Tested bonding passthrough bellow material (EPDM) with cyanoacrylate (super glue) – very good bond strength
  • Added weather stripping to passthrough door
  • Marked location of striker plate on passthrough door jam
  • Trimmed and bonded passthrough bellows
  • Installed passthrough door lock
  • Cut strike plate hole in passthrough door frame
  • Trimmed passthrough door hinge pin to length
  • Disposed of unneeded composite panel
  • Disposed of leftover roof rack material

A note about bonding passthrough bellows:

We got our passthrough bellows from Uni-grip, but they are also available from other suppliers like Total Composites. The bellows are made out of EPDM high density foam rubber. EPDM can be a little tricky to bond, and we tried several adhesives in tests. Cyanoacrylate (super glue) was by far the best and in tests; the rubber failed before the adhesive/bond. It’s actually pretty tricky to bond all of the corrugated bellows surface at the same time, so we found that the only practical way to bond the bellows was to bond one pleat at a time. We trimmed the bellows for a 1 1/4″ overlap.