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Old 07-30-2015, 11:01 PM   #11
Midwestdrifter
 
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Default Re: Overland Build

The vertical cabinet aft of the galley is coming along. Not sure how I am going to do the doors and shelves yet. Maybe 2 doors with a horizontal split? Again I used 1/2" plywood and 1/x2" stock.






The the aft face of the galley is home to the swing away table.

I used this mount. Its a good quality product. It has ratcheting handles and the table can be rotated vertically for storage.
http://www.springfieldgrp.com/produc...ay-table-mount



You can just barely see the mount in the picture below.

The water tank is the blank 40 gal unit below.
http://www.adventurerv.net/amerikart...r-p-27731.html

It is installed directly behind the bench seat and shares its fwd tie downs with the bench seat. There is a total of 8 1/4-20 rivnuts in the floor holding the tank down.



Here is one of the tie down brackets. The base is 1/8"x1" steel angle stock. the straps are 1/8"x1" flats.


The tank itself is made of polyethylene. Which means the only way to add fittings is by welding (spin or hot air) or using a physical attachment method. I chose to use a hot air welder. I used the one below from harbor freight. I also needed PE filler rods. Proper prep, a bit of practice, and some googling had me making water tight joints right off. It went so well that I am considering making a custom under-body grey water tank from raw plastic.

Note that you need to follow the instructions closely to avoid damaging the unit. Also this process is very temperature sensitive, and force sensitive. So do your homework.
http://www.harborfreight.com/welding...ent-96712.html



I have 3 fittings on the tank.
Fill=1.25" smooth bore hose
Vent=1/2"NPT
Outlet=1/2"NPT



The pickup fitting is located in the middle aft face about 2" from the bottom. I formed and welded a piece of PEX tubing to the inside of the fitting prior to welding it in. This lets the pump use all but the last gallon or two in the tank.
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2004 T1N | Overland Conversion in Process Completed...For now... | 187,000 miles | 140" | High Roof | My Build Thread
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Last edited by Midwestdrifter; 07-30-2015 at 11:26 PM.
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Old 07-30-2015, 11:24 PM   #12
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Default Re: Overland Build

I started the long finishing process last weekend. The first step if filling all surface voids with a quality non-shrinking putty. Then sand with 220 grit (start lower if on solid wood)

After the surface was as smooth as possible without breaking through the veneer I started applying the surfacer.

I used this product. It is water based and surprisingly high build. In direct sun it dried enough for sanding in under an hour.
http://targetcoatings.com/products/s...-filler-glaze/



I did 2 or more coats sanding in between with 220 or 300 grit. The result is a smooth grain free finish. I thined it about 25% with water and sprayed at at 45psi using this gun.
NeikoŽ 31216A Air Paint Spray Gun, Gravity Feed | 2.0mm Professional HVLP

The topcoat we chose is a waterborne acrylic alkyd. I sprayed it the same as the surfacer. I will remove my guns filter next time as my flow rate was a bit low.
http://www.sherwin-williams.com/home..._acrylicalkyd/

Here is the bench seat after 1 coat. Note that the only exposed surfaces will be the horizontal one to the right, and the 3/4 of the front on the left.



The line where the surfacer starts is obvious.

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Old 08-13-2015, 05:54 AM   #13
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Default Re: Overland Build

hi--what did you use exactly for your vent fitting on the water tank? ie to relieve pressure when filling & vacuum when emptying?

thanks,
sacha
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Old 08-13-2015, 02:12 PM   #14
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Default Re: Overland Build

Quote:
Originally Posted by shenchman View Post
hi--what did you use exactly for your vent fitting on the water tank? ie to relieve pressure when filling & vacuum when emptying?
I used this fitting. These are spin weld fittings, but they hand weld well.
http://www.adventurerv.net/amerikart...ng-p-1931.html



Edit: I am using a gravity fill method. If you are using a fill method with a pressurized line directly connected to the tank, it may be prudent to use a larger vent fitting. This reduces the risk of filling the tank to quickly and causing it to burst/leak.
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Old 08-18-2015, 11:08 PM   #15
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Default Re: Overland Build

Interesting ideas, I like it
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Old 08-19-2015, 01:42 AM   #16
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Default Re: Overland Build

Progress has been slow this month. Lots of obligations planned vacations etc. I have a week of vacation I need to use, so maybe next week I will make some serious progress.

We started the finishing process on the cabinets. It’s not nearly as time consuming as it first appears. The key is to get the technique down prior to making a mess of things! The galley and vertical cabinet are starting to come along. They will need plenty of minor changes such as doors, wiring pass through and hardware.






The maple butch block countertop for the galley arrived. I will be trimming it soon.






I installed the backup camera and ran its wiring. I am using the same pass through as the solar panels. The wiring uses braided sheathing and runs under the solar panels. I used VHB tape to attach the camera bracket.



I ran a 4x18gauge drop cable down the A pillar and started splicing into various wires in the dash harness. I am splicing the following wires for future use.
  • Reverse Light
  • Dash Backlights
  • High Beams
  • Recirculation Solenoid





I ended up needing to drop fuse block 1 to access the High Beam wiring. On the cables I unplugged I noticed some corrosion on a couple of pins. I cleaned them well and applied dielectric grease. If you are have to drop the FB for any reason I would perform this step.






The reason for the cable drop is to run wires for the heads up switch panels. I have two 45 degree switch panels I will be mounting to the right of the driver. Below are the cut-outs in the overhead cabinet. The switches will include:
  • Recirculate Overide
  • LED Light Bar
  • Air compressor
  • Backup Lights and Camera



Here are the switch panels I am using. They required some trimming to for my application. They accept contura switches. I got mine from otrattw.net

http://www.amazon.com/gp/product/B00...OH3SNFRNLGCHCL

http://www.amazon.com/gp/product/B00...3VFBGIEWBLBQO7


I have one of these light bars in my living room waiting to be installed. Besides being dirt cheap, it seems to be good quality.
http://www.amazon.com/gp/product/B00...HYRMJ6C4PTNS4W



Here are links for the camera, monitor and maple countertop. Thanks to Type2Teach for the camera and monitor suggestions in his thread!

http://www.amazon.com/gp/product/B00...5CVAA3KN73OHV2

http://www.amazon.com/gp/product/B00...EZEGQPIGQFV5X7

http://www.amazon.com/gp/product/B00...LFMA7ZVGJMFHPX
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Last edited by Midwestdrifter; 08-19-2015 at 01:56 AM.
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Old 08-19-2015, 01:48 AM   #17
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Default Re: Overland Build

The awning arrived on Monday. F45 Eagle with pearl grey fabric and electric deploy/retract option. This model will self retract in high winds.



This awning is about 12 ft long, and deploys to around 8ft. Due to the this model being self supporting the mounting considerations are a bit more substantial. I have plastic shim stock and sikaflex 252 on order. Because I have wide rooftop solar panels I cannot use the rooftop mounting brackets (several could be made to work). I will be mounting to the side of the roof above the rain gutters.



The gorillas at the freight carrier managed to find every single weak spot in the packaging. If you order one of these make sure to check for damage and REFUSE the shipment if the casing is damaged in any way. Thankfully I will be repainting this unit so the scratches are a big deal. However, I did have to request new motor side end caps as they were badly cracked.
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Old 08-21-2015, 03:02 AM   #18
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Default Re: Overland Build

Nice build! Looking forward to following your progress.
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Old 08-28-2015, 12:41 AM   #19
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Default Re: Overland Build

I have have the whole week off. Been making decent progress. I would have made more, but the window regulator in my Jetta crapped out on my wife Monday morning. Why can't German cars have decent power windows?

Started welding up the Gray Water tank. I am using 1/4" LDPE. Two 24"x48" sheets set me back about 80$.





The foam for the bench seat finally arrived. My Landlord accidentally took it off my doorstep? Strange business.

The foam is 3" on the bottom and 2" on the back. Both will be covered with 1/2" dacron and have 2 layered removable covers.



The awning comes with some poor excuse for a harness. I am not sure how they expect you to get the enormous plug into the van? They also used grease filled tap splices inside the awning itself... Ridiculous!




This crap is not going to fly on my watch. I rebuilt the harness with weather pack connectors and correctly sized wire.





Then up onto the van it went. I mounted the bracket with 10 1/4" bolts through the van wall. They all had backing plates or large washers.




I had to make shims to compensate for the curvature of the van (in both planes). I used 1/2" polypropylene plastic. In addition 2 tubes of Sikaflex 252 were used to bond the bracket and shims to the van. This is not going anywhere. Note that the apparent gap in the photo below is due to the back corner curving in, this is not typical of the entire length. Also the mounting bracket came from the factory drilled wrong. Not a big deal, 10 minutes with a 1/4" drill bit fixed it up nicely.






Here is a test fit prior to setting with the adhesive.






The awning has adjustable inclination. Due to the shim thicknesses I selected the awning body was tilted about 4 degrees above the horizontal. I ended up adjusting the awning to its maximum downward point which was just about right. As a note, do not trust the stickers with degree markings on them, they are placed by hand and have a large variance!



The first switch bank and the reverse monitor have been mounted.



The Awning control switch and MATE have been mounted in the over-cab cabinet face.



The wiring for the awning control module and switch. Per the Fiamma instructions I have wired the control units power through a NC relay triggered by the ignition switch. This way when the engine is running the awning cannot be accidentally deployed. Excuse the mess, this will all be wrapped up once I get all the runs worked out.




I have a good spot marked out for this little guy. Still need to decide on mounting hardware. Maybe rivnuts? Backing plates would require dropping the headliner.... Not really desirable at this point.



We have been doing the finish work on several cabinets. There is also tons of behind the scenes work, such as running cables, prepping for plumbing etc. These projects just eat up the hours. Sometimes it takes an hour just to drill a hole! Then you get half way into a project and discover you need to complete 2 others first.
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Old 08-31-2015, 11:00 PM   #20
Midwestdrifter
 
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Default Re: Overland Build

The remainder of last weeks accomplishments.

The gray tank is welded up minus fittings.



Getting the top on was a bit of a challenge. I ended up welding tabs inside the tank and using clamps to keep the piece from migrating down due to the welding pressure. Total capacity is around 10 gallons. Dimensions are 36"x7.5"x9.5" externally. Note that for maximum strength and to equalize warping i welded both the inside and outside of all the joints.





Here is the planned mounting location. Drivers side next to the fuel tank. This is directly below the galley, so drain routing should be short.



I have to trim about 2 square inches of material out of the inner side of the body skirt.




Here is a close up of the trimmed area.



Mounted clearance.






The water tank and heater are mounted.



I am working on ideas for the enclosure cabinet where the pump and accumulator will be located.






Ran a ton of wiring. Here is the primary chase. Its located just aft of the galley on the drivers side.



The bench seat is in, hopefully for the last time...




The electrical is in and functioning. So much wiring... The solar controller case fan seems to run whenever the interior temps get over 95 degrees. Its not terrible, hopefully the bench seat bottom will drop it considerably. If anyone wants more detailed review/info on any of the components let me know.



It took 45AH to bring both batteries up to 100% today. Max array output was 265W. The panels are dirty and the AUX bank was around 95%. I am hoping to see 400W peak on average. I will say that the Mate2 and FlexnetDC combo allows for very detailed monitoring. I also have 180 days of solar logging.



Started on bench seat upholstery. This is the slip/under cover. 5/16" staples hold the fabric on.





The Galley paint has been finished. So the next chance I get I will be diving into this monument.

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2004 T1N | Overland Conversion in Process Completed...For now... | 187,000 miles | 140" | High Roof | My Build Thread
Another Random Blog | http://VagariesAbound.blogspot.com

Last edited by Midwestdrifter; 08-31-2015 at 11:05 PM.
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