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There is this mystical line, somewhere between 10,000lb and 15,000lb gross, where truck parts just get big, heavy, and harder to work on. I do not envy the hard work you've put in.

With the circuit board, you can coat with rattle can clear coating spray. Another option is to pot/encase it in hot melt glue (or epoxy if you feel the need). There are purpose made conformal coatings, but they typically are expensive for a one off job. I have wondered if riveting a small...

Its an AWD system (low range is an option at 1.6:1) ABS activation controls slippage. Assuming the van has a decent amount of weigh in it, they do well, even when lifting a wheel. Its not a locked off road machine, but soft sand/snow, crappy roads/tracks, are fine. Its still an 7-9ft tall...

The limits are conservative for liability reasons, so if you are under or less than 3% over, its not a problem.

If you are under the load limit, you can run LT tires. Just choose the pressure accordingly.

Making steady progress. Should be wrapped up for the season this week. Filling the area around the new windows with XPS foam. Most of the new hydronic plumbing for stage 1 is installed. However I am getting air lock in one loop, so I need to move the pump. Stage 2 will involve...

Whats your weight at? What aspect ratio are the tires? If extra width isn't available, you can use length by airing down a higher aspect ratio tire.

Assuming you installed the lines properly, and added a service port, yes. You would need to add extra refrigerant for the lines. It's just a matter of line length and diameter. All these units have a sticker with the charge weight on them.

Relax, it's qualification testing. It will get adjusted down when I put it into service.

Here is the voltage, I tried to smooth out some of the noise, but this about as good as its going to get. Discharge was at about 140A. Charge was at 110A. Here is the tail end of the charge cycle. The discontinuity in the middle is when my laptop went to sleep for a bit.

Did a full discharge test. Called it done at 520AH. Looks like all 560AH are available, but I going a bit conservative. I will post up a graph when I have a chance. Tested the alternator charging and control. For the naysayers about "alternator meltdowns", I had my alternator pegged at...

Sounds like you might need a progressive spring, but from what I gather its not common on ford trucks.

Well, I did qualify with the sky limit... But yeah, not cheap. A set of 2.5s with adjusters would set you back around $2,500. You could sell your current shocks to recoup some of the cash hopefully. I am also not sure what modifications your chassis would need to use a coilover. I am sure...

I got a weak cell fault when testing, so I checked the BMS internal resistance measurements for the first time. They were pretty varied, with one cell over 1mohm, and others near 0.5mohm. I should be seeing around 0.2 max (at mid range SOC, discharge), and about 0.12 nominal. Though it will vary...

If the sky is the limit, I would do coilovers. A good shop should be able to dial in a spring rate and valve package pretty close on the first go. Just need sprung/unsprung weights, travel, ride height, and desired usage.

A few notes as I wind down the testing. The Orion BMS requires some cell taps to be attached to a specific cell when not in use. Failing to do so can cause the ASIC which reads cell voltages to pick up noise, creating a random fault code, which made me think the BMS was failing. The Jr 2 also...

Galley is installed, though I need to finish the water and electrical connections. Should be pretty easy. IMG_20200903_115825689 IMG_20200907_094331629 Ended up directional sanding the top, and using a clear urethane. IMG_20200902_162427165 IMG_20200907_123548150 b I am slowly filling...

Galley is painted, and electrical/plumbing have been fitted, I will get some photos up tomorrow. I have the main plumbing runs for the drains worked out. Just need to make a bracket to support the drain valve and camlock for the hose. Planning forward to rebuild the hydronic system, and...

Looks like CCA, explains the meltdown.

If you jumper cables bypass the shunt, your meter won't see the charge current.