Lee's '04 Chevy Silverado 2500HD and Radica MoonLander camping shell
- Thread starter Lee
- Start date
Thanks!
It turned out better than I originally thought it would, having extra time to think about it helped simplify the final product.
I have considered a mechanical switch under the hood to disconnect the winch.
There are a lot of examples out there using a solenoid to switch the main power off but I think a mechanical system would be more reliable (trading off a little convenience).
The final word in reliability is to re-wire around the switch if it fails.
I haven't looked in to it too much but Blue Sea makes a switch that looks about the right capacity.
I'm not sure if it is appropriate for under hood application (I'm guessing if it is marine rated it will probably be ok)
A switch would allow cutting off the power if something happens to the winch controller and it is stuck 'on'.
I have not seen this personally but I have seen two YouTube videos where this happened, and one of the guys at work had his winch suddenly turn on.
He was using the winch to hold a small boat on the roof - kind of a back up hooked to the front.
Apparently unbolting the battery post power in a hurry on the side of the road isn't fun.
As for soldering cables I'm not a fan.
Wires and cables on a vehicle are subject to a lot of vibration over the life of the vehicle.
A soldered joint is more likely to have a fatigue failure at the end of the solder.
Basically, how far the solder penetrates is not easily controlled, where a crimp with a boot or heat shrink tube has a more controlled strain relief on the wire / cable.
Also it's difficult to control the heat application when soldering a large cable.
I've tried to solder the battery leads on an older GM diesel before, the results where not good (obviously my lack of skill is a factor).
In the end I bought a OEM cable from the dealer.
My 'fix' had corrosion in the copper both sides of the solder, the combination of the stiff splice area and the copper strands disintegrating with green corrosion lead to a quick failure.
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So, if you have been following along, there was a flurry of activity getting ready for our summer adventure to somewhere other than Ohio.
My employer shuts the factory down to do maintenance for the week at fourth of July and the engineering staff also gets off, there’s no reason for us to be off but I’m not complaining.
So I made plans to drive hard to New Mexico, two nights at Chaco Canyon and four nights in the Santa Fe National Forest with a few stops on the drive back to Ohio, all stuffed in to ten days (I added one vacation day at the front of the trip).
So, Friday morning we headed west to St Louis then I-44 South-West for Tulsa.
First tank of fuel with the new 52 gallon tank we went 650 miles before looking for fuel.
With the Moonlander shell, tires etc I get roughly 14 mpg, I need to recalculate with the addition of the hanger bars on both sides holding the awning and the shower tent, I expect some small reduction in mpg.
We stayed in a hotel in Tulsa so day two was going to be another long drive day, or not.
Starting out it was raining heavy but it soon cleared up, and when the road wasn’t wet I noticed we were smoking, grey smoke mostly on the right side.
So I pulled off at the next exit to check it out.
Everything was soaked in diesel from the engine back to the tailgate.
I spent several hours figuring out the exact source, it’s amazing how difficult this was to find and the 95* F with 95% humidity was not helping.
I started by checking everything I touched when I modified the fuel system – it seemed the logical place to start.
I even pulled the fuel filter off to make sure I didn’t leave the old o-ring on the fuel filter housing (I didn't).
Finally, I was sure it was coming from the right side of the engine, so I got a few cans of aerosol brake cleaner and washed that side of the engine.
Sitting in the park and ride lot at the toll road ramp I just couldn’t see any new fuel leaking but after driving one mile to the auto parts store the fuel was everywhere when I stopped.
Finally, with the engine cleaned off I revved the engine to 1500 rpm and went back to check.
Sure enough, it only leaked at elevated rpm, the jumper pipe from the diesel common rail to the injector was leaking at the injector connection.
So, we were in Chandler Oklahoma on a Saturday morning with a busted truck.
There was a Chevy dealer right at the exit ramp, my wife had walked over to use the facilities, and the sales guys had pity on her and entertained her in the air conditioning, but the service department would not be open till Monday.
Chandler OK is not large but they had everything we needed within walking distance.
We limped the truck over to the hotel in town, it’s one of the old hotels along route 66 with individual cabins.
It was old and a bit worn but the A/C worked great (probably still had R-12 freon in it).
We spent the rest of Saturday and Sunday wandering around town, they have a Route 66 interpretive center and a few restaurants (check out the enamel signs and old gas pumps at the bowling alley).
On Monday we walked to the Hertz office and rented a car, then took the truck over to the Chevy dealership.
Transferring stuff to the rental, I grabbed our clothes, food, anything with a lithium ion battery and the propane bottles, I figured there was no need to bake these items in the Oklahoma sun.
At this point we decided to go home, there was little prospect the dealer would get to our truck for a week or two and I didn’t have it in me to plan a rental drive and hotel trip on the fly.
And besides, I had had enough 'adventure' for the week.
On the drive home we did stop at the Chain of Rocks bridge over the Mississippi river just north of St Louis.
I had learned that this was the crossing for the old Route 66 even though it was a private toll bridge at the time.
Chain of Rocks bridge has a kink in the middle to accommodate where the bed rock would support the piers.
Must have been fun to meet a semi just as you got to the kink, yes trucks where smaller back then but still…
Today the bridge is maintained as a bicycle / foot bridge.
Three and a half weeks later the dealer called and told me the truck was ready to pick up.
The only issue was the jumper pipe, the injector end had split and simply replacing it fixed the issue, $430 was all but it's a system I am not familiar with so I don't regret letting the dealer take care of it.
I rented a car to run the trip in reverse, drove down Chandler, 823 miles, on a Thursday, picked up the truck and dropped the rental off on Friday morning.
I asked the parts guy if some one could pick me up at the rental place, one of the sales guys showed up with a brand new 2500 HD Silverado - if my wife had come with me I might have asked what kind of a deal could be made.
I spent $10 at the self car wash place trying to get the diesel off.
Then headed for home.
Along the way, I noticed the Green County Oklahoma Adventure Tour came within 12 miles of the Ok toll road.
I downloaded the GPS track from Overland Trail Guides to my Garmin and made a detour to catch about 25 miles of the GOAT (I know there is a missing letter but it’s what they say).
I stopped in a fairly remote area for this picture, it looks wide and well graveled but this was a repair to a washout.
I’m still getting used to east coast / mid-west overlanding, this trail was a basically a GPS track stitching together any dirt roads in the area.
There was one section that looked like my drive way – two dirt ruts with grass in the middle and, some guys house on one side and his barn on the other (I hope it was a public right-of-way).
But it’s fun to see the back side of the small communities along the way, there was a water hole with a dozen local kids having a swim.
One day I’ll go back and do the rest.
My employer shuts the factory down to do maintenance for the week at fourth of July and the engineering staff also gets off, there’s no reason for us to be off but I’m not complaining.
So I made plans to drive hard to New Mexico, two nights at Chaco Canyon and four nights in the Santa Fe National Forest with a few stops on the drive back to Ohio, all stuffed in to ten days (I added one vacation day at the front of the trip).
So, Friday morning we headed west to St Louis then I-44 South-West for Tulsa.
First tank of fuel with the new 52 gallon tank we went 650 miles before looking for fuel.
With the Moonlander shell, tires etc I get roughly 14 mpg, I need to recalculate with the addition of the hanger bars on both sides holding the awning and the shower tent, I expect some small reduction in mpg.
We stayed in a hotel in Tulsa so day two was going to be another long drive day, or not.
Starting out it was raining heavy but it soon cleared up, and when the road wasn’t wet I noticed we were smoking, grey smoke mostly on the right side.
So I pulled off at the next exit to check it out.
Everything was soaked in diesel from the engine back to the tailgate.
I spent several hours figuring out the exact source, it’s amazing how difficult this was to find and the 95* F with 95% humidity was not helping.
I started by checking everything I touched when I modified the fuel system – it seemed the logical place to start.
I even pulled the fuel filter off to make sure I didn’t leave the old o-ring on the fuel filter housing (I didn't).
Finally, I was sure it was coming from the right side of the engine, so I got a few cans of aerosol brake cleaner and washed that side of the engine.
Sitting in the park and ride lot at the toll road ramp I just couldn’t see any new fuel leaking but after driving one mile to the auto parts store the fuel was everywhere when I stopped.
Finally, with the engine cleaned off I revved the engine to 1500 rpm and went back to check.
Sure enough, it only leaked at elevated rpm, the jumper pipe from the diesel common rail to the injector was leaking at the injector connection.
So, we were in Chandler Oklahoma on a Saturday morning with a busted truck.
There was a Chevy dealer right at the exit ramp, my wife had walked over to use the facilities, and the sales guys had pity on her and entertained her in the air conditioning, but the service department would not be open till Monday.
Chandler OK is not large but they had everything we needed within walking distance.
We limped the truck over to the hotel in town, it’s one of the old hotels along route 66 with individual cabins.
It was old and a bit worn but the A/C worked great (probably still had R-12 freon in it).
We spent the rest of Saturday and Sunday wandering around town, they have a Route 66 interpretive center and a few restaurants (check out the enamel signs and old gas pumps at the bowling alley).
On Monday we walked to the Hertz office and rented a car, then took the truck over to the Chevy dealership.
Transferring stuff to the rental, I grabbed our clothes, food, anything with a lithium ion battery and the propane bottles, I figured there was no need to bake these items in the Oklahoma sun.
At this point we decided to go home, there was little prospect the dealer would get to our truck for a week or two and I didn’t have it in me to plan a rental drive and hotel trip on the fly.
And besides, I had had enough 'adventure' for the week.
On the drive home we did stop at the Chain of Rocks bridge over the Mississippi river just north of St Louis.
I had learned that this was the crossing for the old Route 66 even though it was a private toll bridge at the time.
Chain of Rocks bridge has a kink in the middle to accommodate where the bed rock would support the piers.
Must have been fun to meet a semi just as you got to the kink, yes trucks where smaller back then but still…
Today the bridge is maintained as a bicycle / foot bridge.
Three and a half weeks later the dealer called and told me the truck was ready to pick up.
The only issue was the jumper pipe, the injector end had split and simply replacing it fixed the issue, $430 was all but it's a system I am not familiar with so I don't regret letting the dealer take care of it.
I rented a car to run the trip in reverse, drove down Chandler, 823 miles, on a Thursday, picked up the truck and dropped the rental off on Friday morning.
I asked the parts guy if some one could pick me up at the rental place, one of the sales guys showed up with a brand new 2500 HD Silverado - if my wife had come with me I might have asked what kind of a deal could be made.
I spent $10 at the self car wash place trying to get the diesel off.
Then headed for home.
Along the way, I noticed the Green County Oklahoma Adventure Tour came within 12 miles of the Ok toll road.
I downloaded the GPS track from Overland Trail Guides to my Garmin and made a detour to catch about 25 miles of the GOAT (I know there is a missing letter but it’s what they say).
I stopped in a fairly remote area for this picture, it looks wide and well graveled but this was a repair to a washout.
I’m still getting used to east coast / mid-west overlanding, this trail was a basically a GPS track stitching together any dirt roads in the area.
There was one section that looked like my drive way – two dirt ruts with grass in the middle and, some guys house on one side and his barn on the other (I hope it was a public right-of-way).
But it’s fun to see the back side of the small communities along the way, there was a water hole with a dozen local kids having a swim.
One day I’ll go back and do the rest.