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Lowly Update: While fabricating the subframe I included a couple of cross-bars to help keep the winch cable from drooping down into the underlying components and tearing them out. In an effort to keep them from getting scoured by the cable and kicking off another round of cancerous rust I...

Fusion3 410. 12"x12"x14" print volume. Heated bed, hardened nozzles, enclosed print volume. Not rocket science but it has taken me a couple years to figure out how to get the best results from the various materials. You could get a printer as capable as mine for much cheaper but I chose to...

Plastic of various types depending on the application. Anything critical in nature is printed out of a nylon + carbon fiber filament that is remarkably robust. I've even printed replacement rear sway bar shackles out of the stuff (see post #256 & #272) but haven't been able to fully test...

Lowly Update: Turned my attention back to the 5"x3" rectangular tubing end caps on the back of the subframe that also house the tail lights. I'd already 3D printed a test piece awhile back but it was time to cap off this part of the build (pun intended). I also figured it was a good place to...

Lowly Update: Finished the air tank cradle/strap replacement installation. Turned out pretty good and should allow for the areas between the tanks, under the braces and under the straps to breathe with the hope that it keeps rust from returning with a vengeance. - Sheik

Lowly Update: With the tail lighting mainly complete it was time to turn the attention to the winch's wiring. Keep in mind that the previous winch was hydraulically driven off of the truck's now removed PTO and this new Mile Marker winch is driven off of the truck's 24 volt power. Wiring for...

My RVGlobeTrekker DIY box used Sikaflex 552. No priming necessary on the panels or anodized aluminum per the RVGlobeTrekker guys, just clean the surfaces with lint-free cloth and alcohol. - Shiek

Lowly Update: Took awhile sorting out what wire was for each particular function, especially since the taillights I source off Ebay didn't come with a wiring diagram! Trial and error won out in the end and we were able to get the new taillights wired, labeled and installed. - Sheik

Lowly Update: 18,000 lb electric winch bolted up under the subframe. All 6 bolts lined up with no issues; time to go buy a lottery ticket. Now I've got to figure out how to wire this thing up to the truck's power supply and connect up Lowly's original winch control ports (both front and...

Lowly Update: With the habitat box glued together, it was time to start assembling the parts onto the truck for the habitat to mount to. First order of operations was to fip the subframe right-side up. Once again ExPo member mog's jack lifts came in very handy. Hopefully this will be the...

Lowly Update: Back panel is installed! Glad I was able to foresee the need for additional help on this one as it took 4 of us to position and coax/torture it into place. For those of you embarking on one of these DIY habitats, plan on using more adhesive than you think it will take...

Lowly Update: Back from a summer of raft guiding for long enough to prep and place the lid panel onto the habitat box. A two-man job made possible by reviewing the RV Globe Trekker how-to video, using a handful of ratchet straps, a couple of ladders and the Dewalt battery powered caulking gun...

Lowly Update: The habitat's door and window cutouts were located using the same method of dimensional drawings, templates and thru-hole drilling used on the lid's skylight and vent cutouts. I then proceeded to cut out the door and back-left window as their removal was necessary for running...

Lowly Update: Progress continues at a snail's pace due to summer commitments sitting on various inflatable watercraft and rowing said vessels down whitewater laden rivers until my shoulders and elbows protest in agony. While it is a passion of mine and a pleasure to get paid doing it, I've...

Interesting setup with a center mounted rower and paddlers front and back. I've always been a proponent of a stern mounted rower when running this sort of water, but it looks like a good time! - Sheik

Lowly Update: Finally got the truck running again (dead battery) to get it down to the scales and measure its weight. Wanted to document how much of a diet Lowly has been on since I purchased him. Here's what he looked like off the boat from Wales and how much he weighed (in kg) on our drive...

Lowly Update: Before I could finish running electrical in the lid of the habitat I needed to cut the holes for the fan and skylight. Wiring needed to get to both these voids along with a can light that used the same access tube. I first laid out painters tape in the approximate areas of the...

Lowly Update: There is a need to collect all of the wiring going in/through the lid panel and deliver it to one specific place within the habitat that will serve as the electrical distribution center. This will require a pass-through from the side-side aluminum rectangular tube directly above...

Lowly Update: Once I established what wires needed to go where for each type of circuit, I laid out the placement of the pockets I would be cutting on the underside of the lid panel for the LED can lights: I used a 1" spade bit to pilot drill thru the fiber-reinforced-plastic (FRP) interior...

Lowly Update: Electrical wiring installation is currently underway on the yet-to-be installed habitat lid panel. I'm testing and documenting the various circuit types before I install them to limit the headaches I will encounter once I seal up the lid's edges and lower the lid onto the...