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SETTING UP

Machined Custom Parts

By |March 22nd, 2015|SETTING UP|0 Comments

Today I picked up all the parts for the running gear which were machined for me by George from J&L Engineering. Great man and very meticulous in his work, unlike some of the trailer places where you get told that 2mm play is good enough for a trailer.

Above pictures shows the mounting blocks with brass bushes, the suspension bolts (1.25″) with grease nipples and lock nuts. These blocks are going to be welded onto the trailing arm and are mounted onto the hanger plate with the bolts. It is a perfect fit, with less the .2mm play, just enough […]

Optimising Cuts

By |March 13th, 2015|SETTING UP|0 Comments

Cutting a long, custom made beam is a bit like formatting a long used hard drive. You never feel certain that you do the right thing. If a cut goes terribly wrong you are in trouble because the material is not retainable anymore or only at a great loss. So preparing the cuts is as important to me as the cutting itself.

I had done something like this before I actually ordered the material to optimise the beam length for the best price/length ratio. The longer and fewer beams the cheaper the whole lot with the constraint to meet the […]

Laser Cuts – Suspension Mount

By |March 12th, 2015|SETTING UP|0 Comments

Today I picked up the suspension mounts, counter plate and the airbag mount plate.

The pieces above need to be welded on the main mount plate and the little tabs are for location and strength. Everything fits perfect apart from a little mishap.

Something got lost in translation. I missed to specify the different thickness of the material. The counter plate was meant to be done in 6mm and not 8mm like the main mount. Now I am 1mm out with the distance between the proper mount point of the counter plate and the front edge flange of the mount. I […]

Cleaning Out Shed

By |March 5th, 2015|SETTING UP|0 Comments

The shed is cleaned up and ready to take the chassis. The next thing I have to do is to make some tressels to keep the chassis off the ground and perfectly level, which the floor of the shed is not.

The band saw is in position to cut the beams.

Testing Motorbike Carrier

By |February 14th, 2015|SETTING UP|0 Comments

Originally I had the motorbike on a carrier at the end of the van as most people would think, however there are a few good reasons against it. We have a goose neck trailer so the stability issue is not really as pressing as on a caravan with a larger load at the end. Nevertheless

I wanted to save a s much weight on the van as I could because the weight limits are more critical on the van than on the truck. I have a bit more margin on the truck. So the plan is now to hang the […]

Unpacked and Sorted

By |February 10th, 2015|SETTING UP|0 Comments

Two long days and a lot of sweat in 38 degrees but I got it done. Everything unpacked and sorted. I have a few different places to store everything. The truck transmission is in the truck shed and needs a forklift to get loaded again.

The tanks (10 of them) are in the stables and so are the slide-outs and the shower. The tyres are stowed away out of the sun for later.

All the rest is sorted and spread out in my studio, which I had cleared for the repair of some white ant damage. The open space comes in […]

Picking Up Container Content from the US

By |February 10th, 2015|SETTING UP|0 Comments

Our container was unpacked at the freight forwarder (DB Schenker) because of a requested AQUIS inspections. Customs did not have a problem with it, they did not care to inspect, which was to be expected with the kind of content and origin. AQUIS had a hold on it though and inspection was yesterday but brief, since they were convinced pretty quickly that all items were new, pallets were treated and tyres had no moskitos nesting in them.

So we had the additional cost of unpacking at the depot, but did pick it up and saved the cost for the container […]

Main Rails Delivered

By |February 9th, 2015|SETTING UP|0 Comments

152 x 76 x 6.35 in 6082 Structural Aluminium at 9.90m per length times 5
After a turnaround of roughly three months my main rails arrived to day from Ullrich Aluminum. They were extruded in New Zealand and the shipped here. Capral does produce in Australia but wanted 500kg minimum quantity which is way too much. Four of the five length are around 270kg (that was the minimum quantity).

I have to ask my CAD system about the weight of just the 5 length. I have never really looked at it individually only together with the other components.

It is mighty impressive […]

First Material Pickup

By |February 3rd, 2015|SETTING UP|0 Comments

76x76x6.35 in 6082 Structural Aluminium
Now the procurement phase reaches the end with materials coming in. My container has arrived in Perth awaiting clearance and possible inspection by AQIS (we will know soon). The aluminium profiles for the main rails are also in Perth now (custom made) and we await delivery any day. I am not going to pick up 9.90m long 152x76x6.35 RHS and 5 length of them. My roof rack was at its limits with the weight, but it did ok. It was not far to drive for me and I took it real easy.

Will have to go […]