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I figure that you would have to be young and have no mobility or disability issues in order to utilize that space for sleeping. For me, I would think that 900mm would be the minimum height I could work with. That setup would definitely not be an option for me or my wife, that's for sure, but...

Being a drain, the fitting would not need to withstand much pressure. If it were me, I would just machine up a thin walled stainless hosetail with a parallel end (not threaded) and simply Loctite it into the block. This would be the best method for not reducing flow too much.

Are those 2 bosses on the right hand side of the manifold solid? If so, they seem to be an ideal location for an EGT probe. On my truck there is a similar boss on the dump pipe (post turbo), which is what many people seem to use.

Aren't the design specs from your Chinese supplier provided?

Out of interest... who makes your panels?

At this point I believe that pretty much everyone knows your views on how every company building composite bodies has got it wrong, and that only you know how to do it right. My experience, after building things for over 50 years, is that a lot of time and money can be wasted over engineering...

Your profile says you are from Canada. :unsure:

I have a 110 litre "jerry can" on my truck. :) My setup also includes a self designed/built fuel transfer system, to ensure you're not trying to pump fuel into an already full primary tank.

Looking good. What do the actuators lift?

From memory, you are planning on having two non connected hatches; one in the cab and the other in the camper. If that is still the case, you just need to decide how secure you want those hatches to be, as that will ultimately determine how strong the frame needs to be. Personally, before...

You've asked this before and suggestions were given. As suggested previously, asking specific questions will yield better responses than asking generic questions. Show pictures of YOUR build and detail any specific issues you are encountering.

Normally planning is done prior to making purchases. ;)

As for your air requirements... Have you considered an engine driven compressor?

As much as there are numerous crossovers, structural engineers focus on static, stationary structures, while mechanical engineers design systems that involve motion. Just saying...

Welders get certified by proving that the welds that they do meet the specified standards required. This is usually done via x-ray or destructive testing as part of the certification process. With most welding it generally comes down to penetration, which cannot be seen by simply looking at the...

:)

Yes, it is something that has to be experienced in order to truly understand how bad it really is. Without a load on the back the ride is quite horrendous, and even with a load, it's not all that good. Larger, softer walled tyres and a change (or modification) of springs are pretty much...

I hear a lot of chatter about how hard and complicated it is to design and manufacture a kinematic subframe system. There are numerous variants, some of the main ones being: 3 point, 4 point and spring mounts. All work, but some are more suited to a specific type of vehicle. I would argue that...

There's a lot to be said for that. A retro fit would likely be easier and quicker than building a camper from the start. Don't ask me how I know... sigh!

The 4M50 engine has proven itself to be reliable, but having said that, there is no real way to know how any engine has been treated by previous owners. You can obviously ask questions, but that does not really guarantee anything. Here in Australia these tucks were often used in the rural fire...