Insulating the Cab

After our last snow trip I noticed the carpet under the dog bed was a bit wet from condensation. Need to do something about that. I had planed to insulate the back wall of the cab anyway, it was bare metal panels where the window used to be,  so I had planned to do that for noise if nothing else.

So I ordered a roll of thin foam insulation (I ended up with EZ Cool) and got to work.

Pull all the plastic trims out, pulled the back seat, and rolled the carpet up onto the front seats. I am only doing the rear section at the moment, I don’t have time to pull all the front stuff out too. It takes forever….. Not much insulation from the factory.

Carpet pulled back

Cut a piece bigger than you think you need. All the bends and curves make it shrink!

Piece cut

Then start at one end and work across forming, cutting taping. Don’t forget the holes for seats, seat belts etc! I stuffed it as far forward as I could then made sure it was kind of square and started working towards the back. It bends and shapes ok, not sure easy. But making cuts and taping it seems to get it to hold its shape.

Floor done

Once the floor was done I flopped the carpet back down and started to work on the back walls. much harder, curves, small pieces, slots for the trim panels. But it got done. Spray glue worked great to hold in on the larger flat panels.

Seat belt area.
Up the the back wall.

I also wrapped around the gasket between the box and the cab. Its not a lot of insulation, but any little bit helps. You can see the seats and trims are back in here too. Eventually I will probably carpet the back wall to match the trucks interior, but for now its shiny!

Back together.
Drivers side done as well.

Fix and install Backup lights

So the backup lights have never worked, no idea why. So it was finally dark enough to warrant fixing them. Backing up twisty FS roads in the dusk the previous weekend reminded me….

I had checked the fuses but its a complicated mess. Three fuses, two inside, one under the hood, one relay, the transmission selector switch and the added wring of the box, and tow harness… So I started at the junction box where all the lights connect in the back under the box, everything looked good. Traced the wiring all the way back to the transmission, all looked good. Range switch seemed fine and adjusted correctly. So I went back to fuses again….. There it was, one fuse turned sideways, I was checking the wring one. But new fuse in pace and all better!

But I had decided to add more reverse light. A cheap 20″ light bar should work well. I tied it to the trailer wiring so as not to overload the factory reverse circuit.

A couple of rivnuts in the aluminum plates above the back bumper and I have a spot to mount a light. This was my first use of rivnuts, super handy! They work like a rivet but leave a threaded inset.

Rivnut installed.

A couple of stainless 1/4-20 bolts and the bar is installed.

Light bar mounted.

 

Lights work!

All done!

First Snow Trip of the Year!

The weather called for a good sized winter storm to hit the local mountains, so what do we do? Pack up and head out to try to find snow!

Snow level was still pretty high, higher than the ski area, but we found the highest spot we could pretty easily get to up a forest service road. We had been up there before, but never that high, there are a couple of steep switch backs that had always held us back. So I grabbed a new pair of tire chains on my way home from work and we headed out for an adventure.

Turning off the highway onto dirt it was still raining. We need to get higher!

Turning onto the FS Road

Not long after it started snowing, not hard, but not sticking yet. After getting through the switch backs we made it to 4600′. Not much higher we could easily go, so we found a flat ish wide spot and called it good for the night. IT was snowing and sticking at this point.

Parking for the night

We played in the snow until it got dark and headed inside for dinner. Made a little fire and went to bed for the night.  In the morning I could hear the snow hitting the roof vents, good sign! But I had not checked the fuel for the heater before we left….. It was empty. I had extra, but it took a good 45 minutes to get the lines primed again.

Pretty Morning View
Winter wonderland!

It had snowed bout 3″ over night and was still coming down hard. After a quick breakfast we did some sledding and whatnot. Kid and dog had a great time throwing snow around.

We decided we should probably head down the hill before it got too much more snow. Only one car had come by in the morning, and it was a little slick.

Heading down

Road looked a little different on the way down! Lots more snow. No issues going down the hill, just idled down in first gear. As it turns out in 2WD the whole time…. The front axle is not engaging, one more thing to be fixed. But overall a great trip and fun to play in the snow!

Backup Camera – Utter Failure.

Sooo we needed a backup camera. I had an old phone I figured I would try use as a screen. So I ordered a Wifi transmitter and a camera. Good in theory, not so good behind a huge metal box.

But anyway, the camera and transmitter seem decent, the license plate light was tapped for power, and the camera is powered off the transmitter.

Camera and Transmitter

It was all installed in a tupperware for water proofness, and attached to the back bumper panel with VHB tape.

Now it works, if your behind the truck, not exactly ideal….. As soon as you move past the the back and down the side the signal just drops. Oh well, I guess I need to run wires….

 

Also a cell booster was installed. This works better! Definitely get better signal, but its still slow if the signal is weak. Also there is some interference with FM radio if its signal is weak also. The external antenna is close, but far enough per the install guide, but moving it further away may help. The unit is a WeBoost 4G-x, its in the glove box, and the internal antenna is above the rear view mirror.

Cell Antenna

First long Trip Report!

So a wrap up of the first long trip we have done. 9 days, 2 states, 2 provinces, 3 people, two 100lb dogs. All worked pretty damn well. Truck eats up highway miles like a dream, drives really nice.

 

As always we come home with a list. Need to get clothes storage above the bed done. Getting under it all the time is a pain. Bed also needs a grab handle to help with lifting. Better seals are needed on the back doors. Back bumper needs to go. But all things we can tackle in time.

 

To start we headed from Seattle to Spokane. First night was in Riverside State park. It was hot, but the river was warm enough for careful swimming, there was a good current. Luckily we had a hook up site that night that allowed us to run our little portable AC unit.

Not a bad site.

Riverside state park

There is a little suspension bridge across the river so you can hike up and down both sides of the canyon.

Bridge across the river

Next two nights were spent in the Silverwood Theme park RV campground. It was clean, had hook ups, but exactly zero shade. It was very very hot. But the park was a lot of fun, and water slides are good for cooling off!  We had never gone before and the kid loved it.

Silverwood Site

We got up at 4am to head up to Canada, it was a good 6 ish hour drive and we had a long hike we wanted to sneak in that afternoon. Off to the mountains!

Off to the Canadian Rockies!

We had planned to hike up to the plain of six glaciers above Lake Louise, but upon seeing the line to even get up to the lake we turned around and headed to the campground where we would stay that night. We promptly passed out for a nap. We made some lunch and headed back up later in the afternoon, luckily as we had hoped the crowds had cleared out a bit, we were able to park and head up on our hike.

It was gorgeous, dogs loved getting out of the truck and into the lake. There were quite a few avalanche chutes to cross with lots of snow left.

The next morning we headed up to Takkawa Falls. The second largest falls in Canada I believe. Again getting up very early has its advantages. There is one very tight set of switch backs in the road. Take notice of the directions on how to go up them.

Backing up the switch backs

You have to back up them in larger vehicles, even full size truck have trouble with the turns. Early morning was good, no one else even on the road heading up.

We had breakfast in the parking lot then it was a quick hike to the falls, pretty amazing, especially how far the mist went.

Takakkaw Falls

 

Beautiful views were everywhere, even just the drive back down. Sun just starting to hit the mountains in the distance.

We headed further north to out next destination, Wabasso campground. But on the way we stopped for a hike up the Athabasca Glacier.

More amazing views along the way

The glacier walk was very cool, but its amazing how fast its disappearing.  They loose around 20′ of thickness each year. The visitor center seen in the very back of the second picture, by the green, was built in the early 1900’s and was right at the toe of the glacier at that time.

Athabasca Glacier
Rapidly Melting away

It was a fun hike out and back, we took a guided tour and quite enjoyed it. IT was pretty cool to walk on hundreds of feet of ice, looking down into the crevasses, and just felling it under your feet. Definitely worthwhile.

Our campground for the night was Wabasso, we had a great spot right on the river. It was in the “tent only” loop, but this site is weird and only allows truck/van campers. Not much tent room and lots of roots, so I guess they just decided to do that. One thing to note is the road to Wabasso is terrible, its very old asphalt that is pot holed badly down the outsides. Just be aware of many people driving up the middle.

Wabasso, on the river

We bought a firewood permit here, the Canada Parks have a permit for all you can burn fire wood, $8 at the time. They have dump truck sized piles around the campground. However it was the last fire of the trip due to burn bans.

Beautiful sunset on the river next to our site

We again arose early to head out to our next destination, and hopefully avoid the crowds. We were headed for the hike up the Edith Cavell glacier, but upon arrival to the road up it was gated….. Little did we know that permits were now required. We headed up the road to the nearby ski area, and found a pull out for breakfast.  We did some quick googling which lead us to find out permits are issued at the visitor center in Jasper at 8am daily. Being that we got an early start we still had plenty of time to head to town and get a permit. When we arrived at the visitor center there was quite the line already forming. But we ended up getting a permit for 11am and headed back towards the campground. The only other issue was the road was limited to 21 feet in length vehicles, we are a little over that, but no one said anything. With careful driving we made it just fine. There are a few very tight turns and the road is narrow, but it didn’t cause any issues.

Since we had some time to kill before out 11am slot to head up we stopped by Athabasca Falls. These waterfalls are scattered everywhere it seems! But this one was pretty neat. It had carved a very deep trench through the rocks.

Athabasca Falls
Gorge carved by the falls

Then it was our time to head up to the Edith Cavell Glacier. Like I mentioned the road has restrictions on length, but after driving it I think it’s not a big issue. It seems to me that it’s almost more to keep the drivers who are not super comfortable in their rental RV’s off. Its pretty tight.

Sadly the meadows above the glacier were closed due to a mommy Grizzly having cubs and being aggressive, but the glacier was still amazing.

Edith Cavell Glacier

We hung around for a bit, climbed up the ridge line and took lots of pics. We even got to see a chunk of the glacier break off and come tumbling down, it was very cool and faster than I could get a picture.

The view from the parking lot makes you feel small!

We had a nice lunch here, there was a great breeze blowing through the truck with the windows open and we were in no rush. Not a bad place to hang out. We headed back down the twisty road and spent another night in the Wabasso campground.

We headed out the next morning, leaving the Banff and Jasper parks behind. We headed back to BC and for Wellsgrey Provincial park. There we had a campground reservation way inside the park.

Along the way we stopped and hiked up towards Mt Robson. The hike up to the lakes was much further than I had anticipated, so sadly we didn’t make it all the way. There were lots of people heading up to camp at the lakes towards the base of the mountain. It was still nice to get out of the truck and walk for a couple of hours.

Mt Robson

We made another quick detour as I saw a little spur road that looked like it went down to the river we were driving along. Sure enough it did, but someone had beaten us down there. It would have been a nice spot for lunch, but we took a few pics and left the others to the spot.

Just off the highway

Like I mentioned our camp site was a fair ways inside the park. What I didn’t know if the road was gravel…. But BC parks has done a GREAT job keeping the road up, it been very very well soaked in magnesium chloride, a dust control and bonding agent, it was smooth and we left almost no dust going 40mph down the road.

We did however start to notice some smoke off in the distance. Not enough to smell it, but it was definitely there. This turned out to be the start of a very bad series of fires for the area.

Campsite in Wellsgrey

Nice little campground, right on the river. Lots and lots of mosquitos though. They would flock to the window screens whenever we were inside. We whipped up some dutch oven break and a batch of chili.

The lake just a quick hike from the campground was very beautiful. There is a portage your able to take small boats and canoes through, and many many boat in campsites along the lake. It would be a lot of fun to come back for. The smoke is starting to make an appearance giving the orange glow to the evening. The lake was very cold though, even being very warm out it was not more than you wanted to put your feet in.

Falls at the end of the lake

A crazy storm wind and lighting storm rolled through that evening, just enough huge drops to leave lots of marks in the dust on the truck, and make us run to get the EZ up out in time for it to stop. The lighting was cool, right overhead and all around, but short-lived. It was a nice last night, a little cooler and lots of little trails around the campground.

We awoke the next morning to smoke.  The wind and lightning had started lots and lots of fires around the area. When we got radio service it said 174 fires, and they were evacuating the town we were driving through.

 

Before we left Wellsgrey park we stopped at a few waterfalls. You would never know they were there from driving by, it all seems reasonably flat, but wow there were some amazing ones!

First was Helmcken Falls, wow was not expecting that. The area is volcanic rock, and the streams/rivers have carved huge channels into the ground. It was a quick walk from the parking lot and insanely beautiful with huge canyon.

Helmcken Falls

We then drove a few more miles down the road to the next stop, Dawson Falls. This one was wide and not nearly as tall.

Dawson Falls

And lastly, just before leaving the park was Spahats falls. Not as grand as Helmcken, but wow that was a deep Canyon.  It just dropped off. Very cool to see the way the water can carve through basalt.

Spahats Falls

 

After find the amazing amount of falls tucked away in this park, those were just scratching the surface really, we pointed the truck south and headed home.

Smoke

Sadly the smoke was our view for a few hundred miles. It didn’t clear up until we were back to Kamloops. But the drive home was uneventful .

So all in all 1600 miles, truck worked great, we were all tired, and it was a great little trip.

Outdoor shower

While washing your hair in the sink does work, yes we tried it!, an outdoor shower has always been in the plan. I was originally going to use a standard “RV” shower, but the cutout needed was huge, and it really wasn’t very nicely made.

So I had seen a “shower port” before at some point so I went googling. The one I wanted was a Bullfinch unit. Its really slick, the hose plugs into the unit, and then it is used to adjust the temperature as well. It only requires a 2 3/8″ hole, and has a tiny mixing valve built in. The shower head is also a dish washer style where when you release the button the water stops. Should help with water usage!

Bullfinch Shower point

The shower was installed right above the intake/exhaust for the water heater, not ideal location, but it was about the only spot it fit  nicely.  With the cover closed it sticks out about 1/2″, the cover has a gasket to keep road grime out too.

Shower installed and closed

When you hook the hose up, the water is automatically connected. just adjust the temperature and its ready to go.

Hooked up

And it works! It actually shoots water a long ways….

It works!

I teed into the water lines near the sink, it is supplied both hot and cold. Eventually I will likely add valves to be able to turn it off and drain it for the winter. I’m still a little worried it might freeze, the valve is in the wall basically. One thing to note is that the Bullfinch uses metric fittings! They are Whale fittings, a common push to connect fitting used in Europe. I found them locally at a marine supply store, not hard to find.

Interior connections.

And that’s it for the shower! I need to make a mat to stand on, but it should work nicely for upcoming trips.

Roof leaks – Oh no….. Find and Fix.

Well as we are packing up in the rain for a long weekend, I see what looks like a window leaking…. Its dripping from inside the frame. I looked at the caulk all around the window, nothing seems out of place. Maybe it was running down the body lines, so I smeared more goop on those spots. Didn’t seem to do much but nothing else I could find.

So off we went, we spent the weekend at the Northwest Overland Rally,  great fun, lots of friends we don’t see too often and a nice weekend away. Even if camping in a grass field with 1500 other people isn’t our norm.

Our spot
Friday morning before all the people showed up.

It rained a bit thursday night and Friday morning, but no real leaks.

After we got home I climbed on the roof to look up there. Sure enough the factory sealant had cracked right along the joint from the corner extrusion to the roof sheet metal. Damn. It was actually leaking down inside the body channels and just coming out where it hit the window!

Cracks!

You can just see the dark colored straight lines in the picture above, those are the cracks. They are all the way around…. Luckily there is some butyl in between the corner and roof that has seemed to keep it sealed in most places.

Bad.

It was cracked very badly across the front, luckily there is a large strip of butyl here, so no leaks I could find. But it was not adhered at all, this whole section peeled up.

Peeled and sanded.

I ended up taking a grinder and going all the way around, grinding the middle of the existing sealant to expose fresh stuff to bond to, and to get the cracks out.

Ground down

I will be adding a second layer of polyurethane caulking, Sikaflex 1a specifically, over the existing stuff. It doesn’t bond well to bare aluminum, so a coat of Sika 260 primer was brushed over it. Before that, a scrub brush, acetone and lots of rags were used to get everything as clean as possible.

Not many pics, its sticky messy work, but 8 tubes were used to cover the seams. It was troweled and finger smooshed around. Hopefully sealing and thick and flexible enough to last a few more years.

Sika smeared on

This will take a few days to cure, but I think it should work well. Hopefully it bonds to the existing stuff and gives me a long life flexible seal.

Live edge Dinette Table

We had been thinking of a live edge slab for our table, but coming up wiht small pieces was difficult. We went to a local guy a couple weekends ago, and found a piece that should work!

Its a cedar or Lebanon, a local 98 year old tree that was taken out when the opera house was remodeled.

Raw slab

It will be finished with a satin polyurethane, lots of coats and lots of sanding…..

I made a leg out of a piece of steel, this will be at the outside edge. A piece of aluminum angle iron is attached to the wall to support that side. I drilled and tapped the floor for the table leg.

Supports

Then the top gets set in place and screwed in! It turned out very nice. It’s a little skinny, but makes getting in and out of the benches easier.

Finished

I will give it a couple coats of paste wax once the poly has set for awhile. That will give  it a good wear layer.

Water System

Because we are leaving on a longer trip, we should probably have the water done right? Starting two days before we leave is the vest time right?

Well it was a TON of work but it got done, and we only left two hours late.

To start I had a 30 gallon tank, it just barely fit under the larger bench at the dinette. It was so tight that I had to take the ledges that hold the top up off…. But it just fit. We laid down 2″ of foam insulation  under the tank. Hopefully this will keep it from freezing when outside temperatures drop to -15 (that’s as cold as we have stayed!).

Insulation under the tank
Tank dropped in

With the tank in place, there is just barely enough room to make the connections. I almost got a slightly longer tank, and I am really glad I didn’t.

With the tank dropped in I had to secure it in place. I used a ratchet strap to hold it vertically, and its pinned in by the bench to hold it horizontally.

Tank held down in place

With the tank in place I could start the plumbing. I used pex pipe everywhere I could. Its great stuff, connections don’t leak, its ok with freezing, and a little bit flexible. On the outlet from the tank, I put a T, one side will go to the water pump, the other side has a valve so the tank can be dumped if needed.

Water feed connection

The water runs across the wall/floor and into the other bench, this is where the water pump goes. The water pump being in with the heater should give it lots of heat to keep it warm in the winter. Valves were used both sides of the water pump so it can easily be removed if needed. Reinforced vinyl hose was used either side of the pump to try to keep noise down. Its still quite loud.

 

Water pump installed

The hot water heater was installed next. It needs one hole for intake and exhaust, its a concentric vent. Also a propane connection, and an electrical connection.

Intake and exhaust

So out come the hole saw and one more hole is added. Some careful measuring and drilling a hole from the outside and inside, and I go them to line up!

Heater sitting in place on the interior

The intake/exhaust was glued and screwed into place, and I could then run the propane line.

Outside buttoned up

Propane was connected and it was back to water. Again I used valves so the heater could be drained if needed. I am hopeful that it wont be needed! I still need to run the drain though the floor.

Almost done!

Next up I had to drill the hole for the faucet. Using a diamond bit usually works well, but needs to be kept wet. The trick is kids modeling clay, it works great to make a dam around the hole so it can be kept full of water. Use towels, it will make a mess…

Dam
Drilling
Hole!

Wohoo it didn’t break! The bit walked a little so its not perfectly centered, but oh well, it didn’t break! So a hot and cold line was run up and a threaded adapter was used to connect to the faucet connections. You can also see the hose barb adapter used for the sink drain in the next picture.

Sink connections

The grey water is simply a six gallon jug that sits under the sink. I think this will work well, it also helps track water usage some.

Grey tank is the blue jug

And put it all together and we get hot water coming out of the tap! Now I didn’t get to installing the outdoor shower yet, but the pex pipe can be cut and modified easily.

Hot water!

That brings us to the end of the water part one. It worked great, being able to just wash hands etc was so nice, we never used the water in our old truck at all. We also found out that the sink pull out can go out the kitchen window for showers 😀

More Electrical – And Solar!

Electrical never ends. So many little things that take soooooo much time.

But I got to installing the inverter/charger. Its a 1250w inverter and a 55 amp charger. The inverter is a little smaller than I would have liked, but it was cheap and used, and the charge is well size for my generator and keeping wire size down. The charger should only draw about 5 amps at 120V Ac, so that means I can use a standard 15amp cord and plug, easy.

The inverter charger gets installed. It will have a 1/0 cable running through a 200 amp breaker and then to the battery bank. Making 120V AC takes a ton of amps at 12V DC.

Inverter charger installed.

For my shore power connection, I had planned to use the drivers side tool box. So I needed to run a power cable from there to the inverter. I used flextite electrical conduit for this. It protects the wire and keeps it dry.

Conduit for the wire

I ran the power cable through the conduit, its the male end of the same extension cord I used to wire the truck, I have about 25′ left, that should be enough to hook up to most hookups or get the generator a ways away. I also pulled a pair of 8 gauge wires for my solar connection.

Inside the tool box

It all rolls up nicely inside the tool box.

 

Solar! Yes I am excited. I have two panels and a PWM charger on the roof of our old truck. They always topped the batteries up a little, but never charged all the way. They were always dirty too…

 

For the new truck I am going to try a portable panel. I can park in the shade and have the panels in the sun, throw it on the hood etc. I went with a folding 100W panel, its very thin and light weight, it should be easy to store, this was one of my concerns with a portable one.

Thin!
Opened

I opted to spend the little extra money for the MPPT controller, I went with a Victron, having only the one panel I wanted the extra efficiency I could get using it. I will do some tests to see how the panel actually puts out compared to its ratings.