Wabi-sabi Overland

Habitat Update 3/8/18

Posted on March 8, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

Another big day for the project: we received all of our windows and doors from Tern Overland today. We got everything but the roof hatch, and it should get here in a little over a week (and certainly before we need it!). We spent some time inventorying everything we received, and it all looks very good.

We are especially excited that everything is double glazed so our habitat should stay nice and cozy. All the windows have integrated blackout blinds and screens, too.

Euro Door

Large Over Counter Window

Window Locks and Struts

Cargo Access Door

Small Over Bed Window

Habitat Update 3/2/18

Posted on March 2, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

It’s a big day for the new habitat: our custom habitat kit from Total Composites arrived today! More details coming soon as we get into inventorying everything, but here are a few photos from the day.

We had 2 hours to unload the container, but with the 2 of us and a friend it took less than an hour to unload. Most of the panels are quite light and can be carried by 2 people. The floor panel weighs a bit and required all of us (including the truck driver) to carry it.

The container had a tamper free lock from U.S. customs on it. The truck driver didn’t have a bolt cutter and seemed concerned when he showed up. It took just a second to cut the lock off with an abrasive disc on a grinder.

Truck Update 2/28/18

Posted on February 28, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

Fit checked fenders and measured mount plate size
Fit checked habitat entry stairs on sub-frame
Fit checked passenger side jerry can mount
Made aft fender mount plates
Made passenger side jerry can mount spacers
Received water tank
Received auxiliary fuel tank
Received kitchen cabinets faces
Received weld sealant
Received stainless steel sink
Arranged shipping with Tern Overland for doors, windows and hatches
Purchase chain hoist
Purchased spare tire lifting sling
Purchased spare tire lifting shackles
Purchased welding supplies
Started modifying auxiliary fuel tank
Designed driver side jerry can, aux tank, storage box mount structure
Purchased extra steel strapping for driver side jerry can, aux tank, storage box mount structure
Cut all steel for driver side jerry can, aux tank, storage box mount structure
Cut steel for habitat stare mount
Cut steel for rear under bed storage box mounts
Welded driver side jerry can, auxiliary fuel tank, storage box mount structure
Fabricated tank hold-own clamp

Water Tank

Weld Sealant

Cutting Metal for Storage Mount Assemblies

Driver Side Storage Mount Assembly Layout

Driver Side Storage Mount Assembly

Fabbing Fender Bracket

Fit Check of Storage Mount Assembly

Hab Ladder Fit Check

Kitchen Cabinet Faces

Kitted Steel for Storage Mount Assemblies

Passenger Side Jerry Can Mount

Sink

Spare Tire Lift Hoist

Spare Tire Lift Shackles

Spare Tire Lift Sling

Subframe Layout

Truck Update: 2/18/18

Posted on February 18, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

Ordered sink (Houzer CS-1307-1, Overall size 12.5″ x 14.375″, Bowl 12.06″ x 10.125″ x 6″ deep, stainless steel)
Ordered house systems fuel tank (RDS aluminum tank)
Trimmed aft subframe angle
Fit checked assembled angle on subframe periphery
Removed spare tire mount
Removed more unneeded small bracketry
Received Air Head composting toilet
Received Froli stars (from Froli Systems)
Received mattress and fitted sheet (from Mattress Insider)
Purchased steel for storage accessory mounting
Started weld prep on subframe for periphery angle
Ordered passthrough bellows from Total Composites
Ordered cabinet faces for kitchen from Wayfair
Finished weld prep
Final test fit and clamped periphery angle
Started tack welding periphery angle
Ordered weld seam sealer (Eastwood seam sealer)
Welded periphery frame
Designed mounts for fenders, passenger side jerry can holder, and rear under bed storage boxes
Kitted mount material for fenders, passenger side jerry can holder, and rear under bed storage boxes
Fixtured and welded mounts for fenders, passenger side jerry can holder, and rear under bed storage boxes

Received Froli Stars

Received Air Head Composting Toilet

Steel for Storage Accesory Mounting

Weld Prep on Subframe

Cutting Mount Material

Mount Material Kit

Welding Periphery Angle

Mounts Welded to Subframe

Truck Update 2/11/18

Posted on February 11, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

Ordered special sized 8″ gel foam RV Mattress with organic cotton and fitted sheet (from Mattress Insider)
Ordered Froli Stars mattress springs (from Froli Systems)
Ordered Air Head composting toilet
Ordered and received reversible flow 1250 Fan-tastic fan (from etrailer)
Ordered water tank (from Plastic-Mart)

Started evaluation of weight distribution and placement of water tank
Installed forward shackle receiver and rewound winch cable
Trimmed off unneeded steel in multiple subframe areas
Trued up ends of subframe rails
Finalized layout of subframe
Cut steel angle for periphery of subframe
Drilled mounting holes in fore and aft angles
Fit check assembled angle on subframe periphery

Forward Shackle Receiver

Installed Forward Shackle Receiver & Rewound Winch Cable

Trimmed Unneeded Steel from Subframe

Trued Up Ends of Subframe Rails

Mercedes 435 U1300L Subframe Layout

Steel Angle for Subframe

Drilled Mounting Holes

Cut Steel Angle for Subframe

Truck Update 2/4/18

Posted on February 4, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

We are really happy that our new habitat box is on its way from Total Composites. We received notification that the shipping process started last week. The box should get here around the end of the month / beginning of next month. Total Composites sent us a picture of our habitat ready to ship!

Total Composites Expedition Habitat Ready to Ship

Now that our old habitat box is removed, it is time to get going on our subframe modifications. Our subframe is in great shape, and we are really happy with its layout. Our plan is to remove some unneeded material, make a new perimeter frame, create a habitat ladder mount, add understorage box and jerry can mounts, and add new fender mounts. Unrelated to the subframe but before our new habitat box goes on, we’d like to remove the old spare tire mount and possibly install a new fuel tank if time and availability permits.

To get our subframe work going, we went by a local steel supplier and picked up 138 pounds of steel for the subframe modifications.

Truck Update 2/3/18

Posted on February 3, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

We have been working over the last few weeks to get the old habitat ready to be transferred to the new owner. A crane came this morning and lifted the habitat from our truck to the new owner’s truck. Everything went smoothly. We’ll be ready to start subframe work soon.

Truck Update 1/26/18

Posted on January 26, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

Started process of separating habitat from subframe
Made large jack extension
Rounded edges of receiver tang for forward shackle
Reduced size and weight of lug wrench
Made spacers for forward shackle retention bolt
Cut plywood shims in preparation for hab lift
Separated and lifted hab from subframe

Made Large Jack Extension

Jack and Jack Extension

Rounded Edges of Receiver Tang for FWD Shackle

Reduced Size and Weight of Lug Wrench

Truck Update 1/21/18

Posted on January 21, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

Received Dometic Origo 3000 stove
Received U1300L ambulance jerry can holder
Received torque amplifier
Received lug wrench
Received allen keys for drain plugs
Cooked pasta dinner on Dometic Origo 3000 stove
Received torque wrench
Received “Build Your Own Overland Camper” by Steve Wigglesworth
Installed batteries
Torqued lug nuts
Removed jackstands
Received forward shackle
Fit checked shackle assembly in forward receiver; fillet interference
Organized spare parts

Received Dometic Origo 3000 Stove

Cooked Pasta Dinner on Dometic Origo 3000 Stove

Received U1300L Ambulance Jerry Can Holder

Received Torque Amplifier, Lug Wrench, and Allen Keys for Drain Plugs

Received Torque Wrench

Received Forward Shackle

Truck Update 1/14/18

Posted on January 14, 2018May 4, 2019 by Yvonne @Quilting Jetgirl

Ordered Dometic Origo 3000 Alcohol 2 burner stove
Received hub vents
Drained forward portal axle hubs
Degreased, paint prepped, and painted lug nuts
Installed hub vents
Received tires
Took tires, rims, and dyna beads to tire shop
Picked up finished mounted wheel assemblies
Filled front hubs with Redline Synthetic 75W-90 (GL-5)
Drained and filled rear hubs
Ordered torque multiplier
Ordered 24mm lug wrench
Ordered self-recovery shackle for front 2″ receiver
Ordered torque wrench (so we don’t have to keep borrowing one)
Ordered large allen wrenches for fluid drain plugs
- 17mm for differentials
- 14mm for transmission and engine
Bought high pressure grease
Greased forward U-joints and steering assembly
Mounted newly finished wheel assemblies
Started planning habitat interior cabinet layout