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Monthly Archives: June 2015

Finished Floor

By |June 27th, 2015|CHASSIS BUILD|0 Comments

The floor is completely finished, the capping is not complete yet.

Have extended and connected the ABS sensor lines.

Left to do:
Fitting of right mud flap
Brake controller in truck.
Wiring the brake actuator.
Filling the brake system and bleeding the ABS controller and the brake callipers.
Fitting and wiring the lights. – I am waiting still on my suzi coil trailer cable.
Stamping the VIN number.
Attaching the compliance plate (after the weigh bridge).

That is all is left to do for the registration. Will make an appointment on Wednesday for the next week.

After that comes some testing and then the finishing of the under floor frame […]

Chassis Floor

By |June 25th, 2015|CHASSIS BUILD|0 Comments

Nice weather again today.
The floor was on the agenda today. Was a bit nervous to cut into a $600 panel and make a mistake. I actually did, but not a dramatic one. I did cut the floor already according to the final floor plan, but then realised that it would be a better idea to leave those sections on for now until it is registered or even until I really have to cut it later.
So there is a rectangular hole on the left, which I will fill back in.

I had to make to holes for the rear legs to come […]

Chassis Outline

By |June 24th, 2015|CHASSIS BUILD|0 Comments

I decided on progress over beauty and did the outline angle of the chassis
with MIG instead of Tig. I dialed back the Amps and Volts and was ok
in the corners, a couple of small holes in the flat 3mm but I can live
with that.
I finished the complete outline – the outside angle where the panels get glued on and
started fitting the floor.

I use a t section to support the floor panel joint. The t is 10mm lower than the height of the panel, which leaves a 3mm gap between panels, which will be filled with fiberglass matt and epoxy resin […]

Bigfoot Replacement

By |June 23rd, 2015|COMPONENT BUILD|0 Comments

Replacement for the Bigfoot control unit
Shortcomings of the Bigfoot control unit:
– Slow grounding of legs – only one at a time
– Automatic grounding of legs only as part of autolevel, not separate function
– Left to right position not programmable
– Pumps don’t stop when leg is up until last one is up
– Front to rear angle always 0 in dedicated display mode – works with auto level.
– System can be deadlocked and will not move when angle is too high – no manual override
– System stops when battery is low in retract all mode, does not use single legs for […]

Electrical Signals

By |June 18th, 2015|CONCEPTS|0 Comments

Most of the electrical signals which need connection and processing are defined. There are a few components not yet defined, but the majority is. This list groups the signals by signal type in order to identify the number and kind of interfaces the network nodes need.
The next step is to assign the signal to a location in the van, which then leads to the identification of connection boxes and network nodes and their location. All network nodes are connected via the CAN bus and exchange information with the central system.
Manually switched lights – (can be turned off by […]

Door Profiles

By |June 18th, 2015|BODY BUILD|0 Comments

I found the profiles for the furniture edges, doors, drawers. I was looking for these for some time. Trailstar used them when they were around and built vans. They no longer do. They also used these panels, which are leagues above anything used inside vans by others, but most likely too expensive for the average builder or buyer. The Australian market does not really appreciate quality. Most still think heavy is good.

Now I can use the same profiles for my Duralite panels because I did not like what they have to offer for edging. They door trim looks very […]

One Wire Id

By |June 18th, 2015|COMPONENT BUILD|0 Comments

Also done some electronic stuff. An expansion shield with one wire interface and an ID chip for each can bus node. Now I have to produce a few of them. The Id shield lets me use screw terminals for the Arduino connections and I have added 3 sockets for one wire with a 5V power supply for the one wire bus. One of the sockets is used to connect a id chip giving the component an unique id and the two others are connected to a socket for external use. It can be connected to a temp sensor junction […]

Floor Panels Picked Up

By |June 18th, 2015|CHASSIS BUILD|0 Comments

I can hold one panel with one arm stretched out easy, very light. It is probably the most expensive floor a van can have.

Placed one board on the chassis and had a walk on it. No bending, not any movement under both of our weights with a span of 85cm of the supports underneath. Brilliant stuff, did I say it is expensive !

I measured the tank brackets and made the DXF files for the laser cutter.


Bigfoot Shortcomings

By |June 17th, 2015|CHASSIS BUILD|0 Comments

Weather getting a bit wet.. had only a couple of hours today .. done some TIG welding, killed my last electrode and have to wait for the new ones. My local shop wants $14 for one and on the web I buy 10 at $17 .. I refuse to pay such inflated prices, so I wait.
I should have ordered some earlier, but my practising killed a few.

Had an answer from Quadra Manufacturing about the Bigfoot Levelling system. They actually confirmed that the system is working the way it should, running the pumps on all legs until the last leg […]

Chassis Outline

By |June 16th, 2015|CHASSIS BUILD|0 Comments

I have picked up, cut and fitted the outer angle of the lower chassis.
It creates a flat surface to which the panels are glued and the top edge is flush with the 30mm floor.
The inside of the panel will be glassed to the floor.

I have not finished welding all the angle parts. I first had to brush up on mi TIG skills and adjust my welder to the material. Havn’t done that in a while and it took a moment.
Made a picture of my settings for the 3mm angle joins.

The welds are not crash hot yet, the pulse frequency and […]

More Bigfoot

By |June 14th, 2015|CHASSIS BUILD|0 Comments

Have fiddled today mainly with the levelling system. Have relocated the control box (swapped sides – left to right) and levelling is working ok now, but it is slow and the limiter switches don’t work when the legs come up.
Have checked everything, wiring correct, signal goes correctly into the control box but it does not stop the pump when the leg is up. Control box not working properly. Have written to Quadra – also the level display front to rear shows 0 all the time even if it is not level. Something is not right.

But I have decided to build my […]

Bigfoot Control Panel

By |June 13th, 2015|CHASSIS BUILD|0 Comments

Today I done all the little stuff around the brake lines, putting cable ties at all ends of conduit, tightening the connections, fitted the ABS controller and fitted a temporary home for the control panel of the levelling system.

A waterproof case for now to protect the control panel.
Later the panel sits inside the body and the case will be obsolete.
Had a bit of a problem with the levelling system until I realised that the controller was mounted wrong.
They have specified top, but not left and right. After I swapped sides it worked. Still have a problem with the limiter switches […]

More Welding And Pictures

By |June 12th, 2015|CHASSIS BUILD|0 Comments




Done the hanger for the front grey water tank need a middle brace still. That will come after the registration.

The brake lines are done and the brake locks are in place.

Both steps are done

and the trailer now stands on it’s own feet at normal ride height. Hardly any air in the bags at this stage with so little weight on them right now.




Lots Of Bolts

By |June 10th, 2015|CHASSIS BUILD|0 Comments

A lot of bolts went into their place today. I finally received the washers yesterday after 6 days (within Perth). It took 7 days for some parts from the US, they also arrived yesterday.
With the washers now the remaining bolts could be fitted.
The coupling mount is now completely fixed.

So are the suspension hangers now. The counter plate is shown from the top with the rubber membrane around and pressed between cross members. Nothing is going to move or rattle here. The bolts sit in Nylon sleeves and all bolts are press
fitted into the sleeves.

I also started to fit the […]

Brake Lock

By |June 8th, 2015|CHASSIS BUILD|0 Comments

The shocks are all done and the running gear and brakes are all mounted.
Brake lines are bend and the first wheels are on.

The flexible brake hoses are all in and secured and the steel lines are bent. I have identified the position for my brake locks. Although I had that in the model I did not have the brake lines made including the lock. I first wanted to see where I end up. Now the brake lines are bent and I could confirm the location.

The hydraulic brake lock sits after the ABS controller just before the wheel. The lock is a […]


By |June 6th, 2015|CHASSIS BUILD|0 Comments

Busy again today. Tacked the outriggers on the lower chassis for the floor support and under floor storage hangers.
Will finish welding them tomorrow.

Fitted the shocks now in position. I use two boots for each shock .. not so much that I am worried about the body of the shock, it is the plastic adjuster and the bottom end which needs protection.

Below is the image of the adjuster.

The bottom boot slips over the adjuster and it is mounted behind the shock in driving direction for additional protection.
All precautions for gravel roads. The trailing arms are the only areas which are exposed, […]

Cable Supports

By |June 5th, 2015|CHASSIS BUILD|0 Comments

Done lots of small tasks, producing brackets and mounting cables and brake lines.
Very time consuming, finished the main brake lines from the main actuator to the
Abs actuator and fitted the flexible brake hoses at each wheel and the ABS sensor

Above angles are used to mount the control and power cables for the legs at some part of the chassis.

Fitted the brackets to hold the ABS sensor line in place and avoid rubbing on the wheel. Fitted all the little brackets which we made earlier. Had a bit help from a German backpacker doing a few things for me right now.

Securing […]

Running Gear Mounted

By |June 3rd, 2015|CHASSIS BUILD|0 Comments

Today I have installed the running gear on the right side of the trailer and designed and prepared a couple of mounting brackets for brake lines and ABS cable. Done other bits and pieces including the mounting bracket for the ABS actuator.

When I have fitted the mounting brackets for the brake lines I will then connect the brakes to the ABS actuator.

As I go along I document each step in my Installation WIKI with images .. better than descriptions ..

I have uploaded a sample page of today’s work. For each component I will document how it is installed and/or […]