Truck Update 11/21/18

  • Cut shelves for pantry from 12mm plywood
  • Trimmed edges of pantry shelves with 3/4″ poplar
  • Measured and laid out shelf spacing
  • Bonded and screwed shelf ledges to pantry sides
  • Bonded edge trim to bathroom wall
  • Clearanced and trimmed pantry components
  • Dry assembled kitchen pantry and bathroom wall
  • Fabricated lower shelf and support structure for pantry
  • Bonded in all pantry shelves
  • Made and installed trim around top of pantry
  • Countersunk holes in cabinet face
  • Cleaned and deburred all screw holes
  • Filled all exposed screw holes
  • Sanded filling and paint prepped kitchen pantry
  • Received cabinet door latches
  • Purchased lumber to finish pantry
  • Applied first coat of paint to pantry
  • Applied first coat of pain on lumber to finish pantry
  • Sanded first coat of paint on pantry
  • Sprayed on second and third coats of pain to pantry
  • Sanded pantry doors
  • Started designing storage behind bed headboard
  • Cut and painted shims for spacing pantry from upper kitchen cabinet
  • Cut latch opening in pantry door faces
  • Applied second coat of paint on lumber to finish pantry
  • Started designing passenger side overhead cabinet
  • Painted pantry doors
  • Bonded 1/4″ spacers to upper kitchen cabinet
  • Purchased lumber for storage behind bed headboard and passenger side overhead cabinet
  • Applied final coat of paint on pantry doors
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Truck Update 11/18/18

We have updated our plan for the kitchen pantry a little bit. After doing a number of fit checks, we have decided to build a custom pantry / cabinet instead of using a locker that we had previously planned to use. We may choose to salvage the face of the locker.

  • Updated measurements and revisited habitat passenger side design
  • Fabricated and installed:
    • Under sink shelf
    • Under sink cabinet partition
    • Seagull water filter mount
    • Footman’s loops for securing cabinet contents
  • Applied second coat of paint on kitchen side of bedroom wall
  • Prepped, bonded, and screwed kitchen cabinet top and back wall
  • Cut and sanded pantry door panels
  • Applied first coat of paint to pantry doors
  • Applied felt bump stops to pantry door frame
  • Applied second coat of paint to pantry doors
  • Test assembled entire lower cabinet
  • Disassembled lower kitchen cabinet and prepped for installation
  • Started designing kitchen pantry around locker face
  • Started cutting plywood for pantry sides
  • Dry fit, masked, prepped, bonded, screwed, and installed lower kitchen cabinet
  • Test fit side panel for pantry
  • Purchased lumber for pantry

Truck Update 11/14/18

  • Finished all trim and flanges on bedroom walls
  • Cut plywood for lower bed wall
  • Carefully reviewed wall design and dimensions
  • Bought painting supplies
  • Painted hard to access wall flanges prior to assembly
  • Clearanced bedroom walls for extrusions
  • Fit checked cabinet to driver side bedroom wall
  • Painted difficult to access area on wall behind cabinet
  • Sprayed top coat paint on upper kitchen cabinet and doors
  • Notched baseboard for extrusion
  • Pre-drilled and countersunk assembly screw holes in all wall components
  • Cut 1/2″ wide spacer for bed wall entry area
  • Dry fit, masked, prepped, bonded, screwed, and assembled bed wall into habitat
  • Cut wood to finish bed entry opening
  • Fit riser block to bottom of kitchen cabinet
  • Match drilled holes from riser into bottom of kitchen cabinet
  • Installed bed entry opening finish trim
  • Installed bed wall baseboard
  • Filled exposed screw holes on forward face of bedroom wall
  • Installed hinges and doors on upper kitchen cabinet
  • Disposed of unneeded lumber
  • Dry fit, masked, prepped, bonded, screwed, and installed upper kitchen cabinet
  • Touched up Korapop 225 wall bond where clamps blocked access
  • Started cutting kitchen cabinet faces
  • VHB bond test on painted wood
  • Corresponded about portal axle reservoir tanks
  • Corresponded about speedometer/odometer upgrade
  • Received:
    • Cab speakers
    • Fuel pump primer
    • Air dryer desiccant cartridge
    • Charge controller
    • Battery monitor
  • Started designing bracket for seagull water filter
  • Fabricated and installed shelves, mounting plate, and support spacers inside kitchen cabinet
  • Masked and applied first coat of paint to forward side of driver side bed wall
  • Dry fit, masked, prepped, bonded, screwed, and installed kitchen cabinet riser

Truck Update 11/11/18

  • Purchased the majority of the lumber and plywood for habitat interior
  • Cut wood and started assembling kitchen upper cabinets
  • Finished design and started fabricating bed walls
  • Bonded and screwed lower bed wall member to habitat floor
  • Assembled and bonded upper kitchen cabinet face
  • Ordered cabinet latches
  • Glued/screwed upper kitchen cabinet face
  • Finalized size of plywood for kitchen walls and upper kitchen cabinets
  • Corresponded with Battle Born about charge controllers
  • Requested information on portal axle oil reservoir options
  • Cut plywood for:
    • Kitchen walls
    • Upper kitchen cabinets
    • Bathroom wall
    • Kitchen pantry
  • Assembled upper kitchen cabinet
  • Modified lower kitchen cabinet support base
  • Started painting:
    • Base board
    • Back of lower kitchen cabinet
    • Mid lower bed wall
  • Purchased trim to finish edge of plywood
  • Ordered Victron charge controller and battery monitor from Battle Born
  • Cut and installed upper kitchen cabinet dividers
  • Bonded edge trim to bed walls
  • Filled screw holes and sanded upper kitchen cabinet
  • Sanded edges of bed walls
  • Cut wood for bed support
  • Assembled, glued, and screwed bed support rails
  • Painted upper cabinet
  • Painted lower kitchen cabinet support
  • Received water strainer and accumulator
  • Fit checked, prepped, bonded, and screwed bed support rails into habitat

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.

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.  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.

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