Truck

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.

Masked and Painted Under Counter Riser and Masked and Urethaned Countertop

Masked and Painted Under Counter Riser and Masked and Urethaned Countertop

Installed Slides and Drawers in Kitchen Cabinet

Installed Slides and Drawers in Kitchen Cabinet

Installed Slides and Drawers in Kitchen Cabinet

Installed Slides and Drawers in Kitchen Cabinet

Templated and Applied Sound Deadening Mat to Cab Floor and Firewall

Templated and Applied Sound Deadening Mat to Cab Floor and Firewall

Templated and Applied Sound Deadening Mat to Cab Floor and Firewall

Applied sound deadening mat to underside of hood

Applied sound deadening mat to underside of hood

Applied sound deadening mat to underside of hood

Final Installed Carpet and Rubber Floor Mat – Passenger Side

Final Installed Carpet and Rubber Floor Mat – Passenger Side

Final Installed Carpet and Rubber Floor Mat – Passenger Side

Cutting Carpet to Install

Final Installed Carpet and Rubber Floor Mat – Driver Side

Final Installed Carpet and Rubber Floor Mat – Driver Side

Final Installed Carpet and Rubber Floor Mat – Driver Side

Final Installed Sound Deadening Floor Mat

Installed Arm Rests on Cab Seats

Testing Out Ergonomics of Seat Position

Finished Cab Interior

• 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

Straightened Driver Side Window Track

Final Trimmed Sound Deadening Floor Mat

Applied Sound Deadening Mat to Sheet Metal Areas Behind Glove Box

Applied Sound Deadening Mat to Sheet Metal Areas Behind Glove Box

Reinstalled Glove Box Assembly

Bonded Felt to Top of Dash

Reinstalled Engine Access Cover

Applied Sound Deadening Mat to Interior Surfaces of Doors

Bonded Indoor-Outdoor Carpet to Cab Door Panels

Bonded Indoor-Outdoor Carpet to Cab Door Panels

Bonded Indoor-Outdoor Carpet to Cab Door Panels

Bonded Foam Rubber for Passthrough Acoustic Plug

Bonded Foam Rubber for Passthrough Acoustic Plug

Cut Foam Rubber to Fill Cab Floor Cavity

Cut Foam Rubber to Fill Cab Floor Cavity

Cut Foam Rubber to Fill Cab Floor Cavity

Cut Foam Rubber for Passthrough Acoustic Plug

Fit Checked Foam Rubber for Passthrough Acoustic Plug

Applied Sound Deadening Mat to Cab Floor Cavity Cover

Applied Sound Deadening Mat to Cab Floor Cavity Cover

Received Soft Close Ball Bearing Drawer Slides for Kitchen Drawers

Sealed Doors with Plastic and Double Sided Tape

Sealed Doors with Plastic and Double Sided Tape

Reinstalled Carpeted Door Panels

Reinstalled Carpeted Door Panels

Applied Sound Deadening Mat to Cab Floor Cavity

Applied Sound Deadening Mat to Cab Floor Cavity

Assembled, Bonded, and Screwed Kitchen Drawers

Assembled, Bonded, and Screwed Kitchen Drawers

Assembled, Bonded, and Screwed Kitchen Drawers

Reinforced Kitchen Drawers with Half Inch Poplar Strips

Bonded and Screwed on Kitchen Drawer Faces

Bonded and Screwed on Kitchen Drawer Faces

• 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

Cut, Fitted, and Sanded Wood for Under Countertop Riser

Assembled, Bonded, and Screwed Under Countertop Riser

Assembled, Bonded, and Screwed Under Countertop Riser

Assembled, Bonded, and Screwed Under Countertop Riser

Fabricated Structure for Under Counter Slide Out

Fabricated Structure for Under Counter Slide Out

Fabricated Structure for Under Counter Slide Out

Fabricated Structure for Under Counter Slide Out

Designed, Cut, Bonded, and Screwed Under Stove Support

Designed, Cut, Bonded, and Screwed Under Stove Support

Designed, Cut, Bonded, and Screwed Under Stove Support

Test Fit Sink, Faucet, and Stove

Test Fit Sink, Faucet, and Stove

Created Outlet Cutout in Face of Cabinet

Bonded Scrap Oak for Slid Out

Cut Slide Out to Final Size

Cut Slide Out to Final Size

Final Assembled Slide Out

Final Assembled Slide Out

Drilled Mounting Holes and Test Mounted Alcohol Stove

Drilled Mounting Holes and Test Mounted Alcohol Stove

Drilled Mounting Holes and Test Mounted Alcohol Stove

Drilled Mounting Holes and Test Mounted Alcohol Stove

Test Fit Sound Deadening Floor Mat in Cab

Marked Areas to Trim in Sound Deadening Floor Mat

Marked Areas to Trim in Sound Deadening Floor Mat

Trimmed and Cut Away Extra Sound Deadening Floor Mat Material

Trimmed and Cut Away Extra Sound Deadening Floor Mat Material

Trimmed and Cut Away Extra Sound Deadening Floor Mat Material

Trimmed and Cut Away Extra Sound Deadening Floor Mat Material

Received Battery Cables

Made Templates for Wool Felt for Engine Access Door, Glove Box, and Top of Dash

Made Templates for Wool Felt for Engine Access Door, Glove Box, and Top of Dash

Cut and Trimmed Felt Insulation for Cab

Cut and Trimmed Felt Insulation for Cab

Cut and Trimmed Felt Insulation for Cab

Bonded Felt to Engine Access Cover and Glove Box Door

Bonded Felt to Engine Access Cover and Glove Box Door

Bonded Felt to Engine Access Cover and Glove Box Door

Cleaned and Applied Sound Deadening Mat to Back Side of Glove Box

Cleaned and Applied Sound Deadening Mat to Back Side of Glove Box

Cleaned and Applied Sound Deadening Mat to Back Side of Glove Box

• 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

Painted Driver Side Seat Mounts

Painted Driver Side Seat Mounts

Painted Passenger Side Seat Mount

Painted Passenger Side Seat Mount

Machined New Bushings, Pins, and Rollers for Driver Side Suspension Seat

Machined New Bushings, Pins, and Rollers for Driver Side Suspension Seat

Machined New Bushings, Pins, and Rollers for Driver Side Suspension Seat

Machined New Bushings, Pins, and Rollers for Driver Side Suspension Seat

Machined New Bushings, Pins, and Rollers for Driver Side Suspension Seat

Machined New Bushings, Pins, and Rollers for Driver Side Suspension Seat

Machined New Bushings, Pins, and Rollers for Driver Side Suspension Seat

Machined New Bushings, Pins, and Rollers for Driver Side Suspension Seat

Machined New Bushings, Pins, and Rollers for Driver Side Suspension Seat

Machined New Bushings, Pins, and Rollers for Driver Side Suspension Seat

Machined New Bushings, Pins, and Rollers for Driver Side Suspension Seat

Reassembled Driver Side Suspension Seat

Reassembled Driver Side Suspension Seat

Purchased Material to Start Kitchen Cabinet Built

Started Building Lower Kitchen Cabinet

Started Building Lower Kitchen Cabinet

Started Building Lower Kitchen Cabinet

Started Building Lower Kitchen Cabinet

Started Building Lower Kitchen Cabinet

Started Building Lower Kitchen Cabinet

Started Building Lower Kitchen Cabinet

Started Building Lower Kitchen Cabinet

Shift Linkage Assembly Diagram

Removed Entire Shift Linkage to Fix Unacceptable Shift Slop

Removed Entire Shift Linkage to Fix Unacceptable Shift Slop

Cleaned, Disassembled, and Inspected Shift Linkage

Machined New Bushings and Pin Assembly for Shift Linkage

Machined New Bushings and Pin Assembly for Shift Linkage

Machined New Bushings and Pin Assembly for Shift Linkage

Machined New Bushings and Pin Assembly for Shift Linkage

Machined New Bushings and Pin Assembly for Shift Linkage

Machined New Bushings and Pin Assembly for Shift Linkage

Reassembled Gear Shift Assembly

Reassembled Gear Shift Assembly

Reassembled Gear Shift Assembly

Reinstalled Shift Linkage

Reinstalled Shift Linkage

Reinstalled Shift Linkage

Put Reflective Tape on Front Bumper

Bonded Red Oak for Kitchen Countertop

Bonded Red Oak for Kitchen Countertop

Bonded Red Oak for Kitchen Countertop

Cut Kitchen Countertop to Size and Sanded Surface

Cut Kitchen Countertop to Size and Sanded Surface

Cut Kitchen Countertop to Size and Sanded Surface

Finalized Layout of Kitchen Counter Cutouts

Trimmed Down, Sanded, and Blended Sink Flange

Trimmed Down, Sanded, and Blended Sink Flange

Trimmed Down, Sanded, and Blended Sink Flange

Cut Hole for Sink in Kitchen Countertop

Cut Hole for Sink in Kitchen Countertop

Routed and Bullnosed Sink Cutout

Routed and Bullnosed Sink Cutout

Drilled Plumbing Hole for Kitchen Faucet

Routed Cutout for Stove in Kitchen Countertop

Routed Cutout for Stove in Kitchen Countertop

Received Breakers and Switches

Received Breakers and Switches

• 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.

Fabricated, Painted, and Installed Plates to Secure Center Dash Panel

Fabricated, Painted, and Installed Plates to Secure Center Dash Panel

Fabricated, Painted, and Installed Plates to Secure Center Dash Panel

Fabricated, Painted, and Installed Plates to Secure Center Dash Panel

Started Using Entry Ladder

Drilled Passthrough Door Deadbolt Lock Hole

Drilled Passthrough Door Deadbolt Lock Hole

Prepped, Primed, and Bonded Passthrough Door

Prepped, Primed, and Bonded Passthrough Door

Prepped, Primed, and Bonded Passthrough Door

Masked and RTV Sealed Cab Side Passthrough Frame

Masked and RTV Sealed Cab Side Passthrough Frame

Masked and RTV Sealed Cab Side Passthrough Frame

Cleaned Passthrough Bellows Materials

Tested Bonding Passthrough Bellows Material (EPDM) with Cyanoacrylate (super glue)

Passthrough Door Hinge Detail

Trimmed Passthrough Door for Better Fit Using Belt Sander

Passthrough Door Hinge Detail

Added Weather Stripping to Passthrough Door

Trimmed and Bonded Passthrough Bellows

Cut Strike Plate Hole in Passthrough Door Frame

Installed Passthrough Door Lock

Installed Passthrough Door Lock

Finished Passthrough Door

Finished Passthrough Door

Finished Passthrough Door

• 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

Fabricated Lower Aft Marker Light Brackets

Installed LED Bulbs in Lower Aft Marker Lights

Fabricated Backup Camera Mount

Fabricated Backup Camera Mount

Fabricated Backup Camera Mount

Fabricated Backup Camera Mount

Fabricated Backup Camera Mount

Fabricated Backup Camera Mount

Fabricated Backup Camera Mount

Replaced Fog Lights with New LED Lights

Bonded on Lower Rear Marker Lights

Installed Passenger Side LED External Strip Light

Installed Passenger Side LED External Strip Light

Final Wired Passenger Side LED External Strip Light

Started Wiring Lower Aft Marker Lights

• 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