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Ready For The Body

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

The last few days I finished the floor and prepared the chassis for the trip to QLD. I still had a very small leak in the airline around the load share valve, but it is now fixed. I also connected a few more cables to the load share valves and the brake locks.

Shaun was so kind to organise the glue for me. Sausages of 600g with KD Bond. Of course a German product for the Teutanic.

I used an air gun to apply the glue. For the whole floor I used 13 of the sausages, which makes another 7+ kg.

The […]

Load Share Air Line

By |October 7th, 2015|CHASSIS BUILD|0 Comments

Today I connected the load share valve for the air line between the two airbags on each side. After it was done and working I tested the suspension and timed the pressure equalisation between the bags and discovered that it was simply not sufficient. The valves I had used restricted the flow too much and so did the 3/8 plastic tube. Not good.

The load share between the bags is a valuable feature especially on rough roads. I also want to study the suspension characteristics with and without load sharing and in order to do that I need to make […]

Overdue Update

By |September 30th, 2015|CHASSIS BUILD, COMPONENT BUILD|0 Comments

If you read this on facebook you are missing 11 images. Only the website has all the images in a post.

Ten days now since I posted last. Lot’s of things were happening including some rubbish removal and clean up, electronic work, many little things on the chassis, my commercial project, some kite surfing, fitted the exhaust of the truck again  and some more shopping for parts.

More than 20 years of my IT history went into the rubbish. A shame really, all still working but nobody would use a 21″ tube screen anymore. I also dumped my NeXT computers, […]

IT IS DONE – Finished Welding

By |September 20th, 2015|CHASSIS BUILD|2 Comments

Last three days were busy with finishing all the little bits of the frame and TIG welding them together. Yesterday I finished the last pieces and then my mate MIG welded the riveted frame components to the thicker chassis pieces.

The outriggers in the front were welded to the neck frame.

The front panel support rail is fitted.

All the frame components for the underbelly cover are fitted and welded.

It is handy to have the strong hydraulic legs to lift the chassis. Easy access from underneath, however the manufacturer recommends not to use them for changing tyres. We should have used axle […]

Underfloor Storage Frame Finished

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

well almost.  Just a few bits left on the rear right. I also added a few of the underbelly cover supports. These are t-sections across the underside of the trailer. These will be used to hold the cover sheets of alu honeycomb 6mm panels. These panels will cover the whole underside from front to rear.

I have to do a few more of these tomorrow and then the lot will be welded. In the middle section is a bit more to do because the trailing arms require a bit extra work to go around them and cover everything else.  I […]

Underfloor Frame Welded

By |September 15th, 2015|CHASSIS BUILD|0 Comments

Today I continued with the underfloor frame in the front and on the right side.  The front is finished and the right side is half done.

In the afternoon a mate came by and helped me with the welding.

All the frames, which are finished so far, are now welded together. We used the TIG welder for all the 3mm to 3mm alu.

The connection between the frame and the thick chassis components will be done with the MIG welder.

As it looks right now I will be finished with all the frames and the supports for the underbelly cover by Saturday evening, […]

Under Floor Frame Continued ..

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

Today I continued with the frame in the front left of the chassis. Takes a while, pretty fiddly to get this nice and straight.

I have checked some measurements from the plan and took some baggage doors to the chassis to double check positions. My wife and I and a bit of a discussion about pull out table in the front, table height, pass through shelf to the kitchen and door position and a couple of other things.

Looked a seating height with the pull out table outside, opening direction of the door and the placement of the door. I am […]

Under Floor Frame

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

After two days of work on my commercial project and rain yesterday, the weather was better today and I done some work on the trailer again.

I did do some more programming for the BMS, which is now almost done. Need a couple of parts and need to put it in a box.

Outside I started the work on the last chapter of the chassis build, the under floor frame for the storage boxes and the underbelly cover.

I also have finished all cutting for the outriggers and side rail for the neck section. The pieces are waiting to be welded.

I tried […]

It is on again – Start of the kite season

By |September 9th, 2015|CHASSIS BUILD|0 Comments

at least for me .. Some of my kite friends have been out all winter but this winter was really not very nice in terms of kiting opportunities.

This was the first time I was out in some time, and unfortunately it was not that great. Beautiful day at the beach, nice water, but just not enough wind and I did not pack the big gun. I trusted the actual reading too much and it dropped as per forecast. The boys at the bureau got it right this time and I did not believe them. Tough luck .. next time […]

Holding Tank Plumbing

By |September 7th, 2015|CHASSIS BUILD|0 Comments

Today was a real warm spring day, the first taste of what is to come now – kite season. We had a seabreeze, just right for a big kite, but I was busy .. Wednesday looking good though although the forecast says otherwise, but our seabreezes never listen to the forecast.  Back to the subject – plumbing.

I finished the cold water and drinking water plumbing, the hot water was already done. After the water supply was no finished, the holding tanks were the next on list.

I placed the shower basin in it’s spot to check the drain, I had […]

Hot Water Plumbing

By |September 4th, 2015|CHASSIS BUILD|0 Comments

After I finished the data entry for the BMS I went outside to do some more plumbing. Yesterday evening I had picked up some more insulation for the hot water pipes as one can see in the top picture.

I looked at the possible routes for the pipes and decided that some of the fill lines were in the way. I removed them to get a better route for the hot water.

I use cable tie saddles to fix the pipes to the chassis.

The saddles are riveted to the floor supports with pop rivets.

In the foreground one can see the hot […]

Hot Water Plumbing

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

As I mentioned before, I went against my initial thought and decided to use PEX with crimp fittings for the hot water and heating pipes. Today I started putting the hot water pipe in and done a few fittings with the crimp rings. Looks very solid and I think I am going to trust that. Cutting the PEX pipe is easy with a dedicated cutter, very clean ends and the crimping with the ratchet tool is simple.

I used the PEX pipe from the roll, which can be a bit daunting, but buying straight pieces would not really helped the […]

Holding Tank Valve

By |August 30th, 2015|CHASSIS BUILD|0 Comments

Not getting ahead really well at the moment. The plumbing is not my strong side and it gets a bit boring, however it gotta be done. Today I had to take a step back before I could make a few small steps forward again.

I had to relocate the rear holding tanks. It is a real pity since they were sitting very nicely, however they were too high and there was not enough space between the top of the tanks and the floor. I did not want the inlets going into the side, I want them straight in from the […]

Hot Water Supply

By |August 29th, 2015|CHASSIS BUILD|0 Comments

Today I only did a little bit of practical work. The lower pressure side for the water tanks is finished. I now started looking at the routing of the pressure lines, specifically the hot water supply lines. The cold is trivial and I have already placed the drinking water lines. For the drinking water I have only 3 connection points and for the fresh and hot water I have 5 and 4 respectively. This is not really a complex installation. The tanks with all the valves and connections have been more laborious.

The main aspect of the hot water supply […]

Filler Lines Finished

By |August 28th, 2015|CHASSIS BUILD|0 Comments

The filler lines and all the breather lines for the drinking water and fresh water tanks are finished. Have to finish a couple of outlets for the drinking water, the fresh water is also finished.

I also had to fit the last tank brackets for the diesel and one drinking water tank.

The images below show the brackets and also the cross brace underneath the chassis, holding the tank hangers and pressing against the cross member to eliminate upward movement of the tanks. This is all pretty solid now and will withstand bad abuse even when the tanks are full or […]

Plumbing Almost Done

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

Continued today with more plumbing work and fitted more tank brackets along the way. Top image shows another support bracket for piping, making sure nothing is going to move when driving over some bad corrugations.

The images above show one of the drinking water tanks held between two angle brackets, stopping any forward or backward movement. All my braces run perpendicular to the driving direction and are primarily aiming to hold the tanks when accelerating or decelerating. All tanks also have a top brace to avoid jumping up on really rough ground.
I am almost done now with the intake side and […]

More Plumbing

By |August 26th, 2015|CHASSIS BUILD|0 Comments

Done more plumbing work today. This is getting real boring, however quite important to make sure that everything is absolutely solid, does not move or rub anywhere and will withstand any abuse by road or temperature.

It took  some time for me to decide what pipes and fittings to use. Until recently I still thought I am going to use pex and push in fittings for the hot lines, but not anymore.

I made some tests after the disaster with the push in air fittings. I used the pex fittings and made a pressure connection with my compressor hose and pumped […]

Load Share Valve

By |August 26th, 2015|CHASSIS BUILD|0 Comments

A couple of days ago I received my air solenoids for the suspension system. These are electric actuated pressure valves are used to connect two airbags and equalise the pressure. They have a pressure input and a NC and NO output. 12V operated they are driven by a microprocessor and a local switch. The purpose is to make sure both airbags on one side have the same pressure while the air level system lifts the van to the pre programmed position. Because the wheels in a closed coupled system are so close together the height sensor on one wheel […]

Fresh Water Plumbing

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

Today I resumed installation of the water tank connections. Had to get a few more hose clamps. I had been thinking a while what to use for inlets and outlets, if I should use pex or push in fittings with standard 12 mm piping etc.

One reason I use food grade hose and hose clamps with poly fittings is weight again. I have motorised ball valves at the inlets and outlets of each tank, they already add up in weight. A lot more brass fittings would considerably add to the weight.

I will use pex for the hot water connections where […]

Manual Air Control

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

Another kg of unaccounted weight .. they will be gone by the time I am finished.
went and got the bits to finish the airlines.

Top image shows my manual backup solution for the air level system. I am not going to use the switches, at least no intention in the near future to wire them up although I could. I will mount 4 Schrader valves for manual inflation if everything else fails. It was cheaper to buy the unit with the switches than individual twin needle gauges.


Done some more electrical stuff. This is one box with waterproof plugs, they will […]