I started on the roof rack, its purpose is to hold a couple of kayaks and act as a mounting point for some LED lights.
There wont be much room up there once the cab air conditioning unit is fitted and the aerodynamic drag reduction system is fitted.
The will be a small amount of space for non mission critical stuff.
I started on what i call windscreen protection, essentially its two steel bars that run vertically from the bumper up the front of the truck art the sides of the windscreen, they connect to the roof rack at the top.
The point of this is that any branches that would normally hit the screen will instead contact the steel bars and be deflected up and over the cab, effectively protecting the windscreen from the branches.
i started by removing the corners of the cab and attaching some 40mm x 6mm steel directly to the chassis of the cab, this only has to support the 40mm box section upright, i used 2mm wall thickness here to keep the weight down on the cab. Bearing in mind i will be adding two massive seats and two more seats as well.
the brackets on the cab will be bolted to the uprights with m12 stainless bolts and locknuts. there will be a n additional bar going horizontally between the two uprights at the bottom of the windscreen, this will serve to mount some LED Light bars onto.
Today i finished the Webasto Cab Heating system. I fitted a 2000ST 2Kw diesel powered heater, as there is no water cooling on the engine an alternative source of heat is required.
I coupled the 2000ST to a MultiControl HD, its the latest controller from Webasto and enables the heater unit to be used as a ventilator as well as all the usual timing functions. It also looks pretty cool.
the exhaust runs through a silencer and out under the passenger side of the truck.
Whilst working on the dash, i noticed that there was a slight bit of play in the steering column. On further investigation i found it was the universal joint between the column and the steering box. \\It was a simple and cheap job to replace the UJ with a new one.
Today with the help of my buddy Andy Linton (thanks andy) we managed to work out the complex hazard warning switch with its multiple wires.
Once again an old type Bakelite switch similar to the ones Noah used on the Ark.
It was the last one to sort out, so now all the dash switches are working and looking good.
Heater controls next, then that's the dash finished.
There wasn't really anything wrong with the dash switches and for the most part they were all working,
However the switches we labeled with generic symbols and it was not really apparent what they really did, That and the fact that they were scattered around the dash with no semblance of order at all.
The same goes for the warning lights, i think they were shaken up in a box and thrown at the dash that had random holes in even more random places.
As well as all that the switches looked very "dated", now it's not a new truck by any means but they really looked old.
I am afraid my OCD got the better of me and they all had to go. First i moved all the warning lights to the top of the dash all in one line.
Then removed all the switches, cut out holes for the new ones and refitted it all, i had to fit blanking grommets in some holes, but managed to loose most of them behind the new holes.
There is a digital control for the cab heater to be fitted yet.
Yes it was a lot of work but it looks a lot better now, and its more functional.
I got a chance to fit the bumper today, The usual hassle with bolts not lining up, but it went on in the end.
I like it, it worked out well. Next thing is to wire the cab switches so i can turn the lights on and take a look at them, maybe a bit of alignment as well.
There is a lot of work gone into this front bumper, I hope its worth it. To be honest it is starting to look the way i imagined it, so that's good.
I now have all the lights mounted in the bumper and wired too the multi-pin connectors, the mating connectors are wired to the truck.
Next step mounting the bumper and testing the lights.
There is three 55watt HID units per side, one is the main truck lighting (Head/Dip) the other two are switchable interdependently and for (Off Road ) use !
i have used LED strips to light up the three lenses on each side, my hope is that it will give enough light to suffice as side lights. I do not really want to add anything else that will take the look off it.
We will see !!
I am very happy today, i just got to the bottom of a wiring fault that has been bothering me for some tome now.
when i collected the truck from the Czech Republic i was a bit excited, as a result i didn't really scrutinize the electrical systems as much as i should have.
I knew that i could easily fix any problems.
Obviously i checked all the lights,horn,and important stuff, but this particular fault is something you just wouldn't look for, so i didn't spot it until we were in Germany on the way home.
I got the guys in the Czech Republic to fit the more modern indicator stalk to the truck for me, it controls main beam flash and on/off and also wipers intermittent/slow /fast, washers and horn. Its a lot neater that the old type controls.
on a coffee stop i removed the key from the ignition,
when getting out of the truck i knocked this indicator stalk and inadvertently switched the intermittent wipers on. The wipers didn't come on, BUT the ignition did. Not ideal.
The guy that wired it probably didn't notice this because its not something you would look for, however he was aware that the intermittent wipe function was not working on the stalk, because he had wired a separate switch for that on the dash (very amateur)
the way it was done, meant that if it was just raining slightly you turned the dash switch on, then if it rained heaver you turned the stalk switch on. Of course when it stops raining you then have to turn two switches off.
So for the last two days i have been tracing this fault.
what i had to work with was:
a stalk switch with a 8 pin and a six pin connector on it (nothing labeled, no documentation for it, not originally off this truck) making this a real pain to work with.
An intermittent wipe relay with 7 pins (i managed to find the pin-out connections for this)
a wiper motor with 5 connections (standard to the truck, so i had the wiring diagram for it)
After struggling for several hours with this i decided on radical action, i removed the wiper motor, stalk switch and relay for the truck along with the associated wiring loom, i stripped the loom and opened it all up and put it all on the bench to work it out.
As it turned out the fault was on the truck ! They had mistakenly wired a ignition feed to the output of the intermittent wipe switch.
Once i found this and tested my theory, i remade all the looms and refitted them to the truck, i also took a closer look at the timer relay and noticed it had a input from the screen washer switch, to operate the wipers when the screen washer is pressed, it was not wired, but is now !
So, long story short, i now have a stalk switch that works properly, no tacky extra switch for wipers, and as a bonus i have wash/wipe function as well.
Done another little bit on the front bumper, i have one of the light sub frames test fitted and some holes in the bumper, my poor punch is having a hard time with the 4mm steel.
I still have more work to do on the light sub frames but just wanted to take a look at the overall effect.
I decided to remodel the front bumper a bit by removing the standard headlight arrangement and replacing it with 3 Hella 90mm HID projector type lights on each side.
The bumper is made from 4 mm steel, so it took a bit of precision cutting and welding, its not finished yet but i made a good start.
I will punch the 100mm holes in the new steel with a 15ton hydraulic punch, the light units will be mounted on a sub frame so that the lenses are flush with the bumper,
Ok, so just to break the monotony of the steel body frame, my wife was at the workshop today and she took a few random pictures (she is very art'y) some of the truck and some of random tools etc.
Here they are.