Lowly the Lorry. . .

[jaleel_da_sheik]

Lowly Update:

With the tanks back in the shop I was able to start fitting the components to turn them into working diesel and grey water tanks. The diesel tank/box has the following hookups: compressed air, diesel heater pickup, level sensor/sender, breather, engine diesel pickup & return, drain valve, fill port.




Next was the grey water tank/box. The tank had the following hookups: inspection/rinse port, level sensor/sender, effluent intake, breather, drain valve, tank defrost loop bungs, cleanout port.

The box attached to the grey water tank had the following connections: compressed air, tank defrost loop, engine defrost loop, diesel heater & electronics port, valve electronics port, diesel heater air intake port, diesel heater exhaust port.


The 3D printer was once again fired up to make parts for the various pass-through components and for the diesel heater system that was going to be mounted inside the box attached to the grey water tank:


Brackets for holding the components onto the diesel system mount plate:


Printed a flexible dust/waterproof? seal for the fuel and electrical pass-thru:


Things 1&2 were put to use assembling the heater system mount plate:


Once assembled the panel was mounted into the box:


- Sheik

 

[jaleel_da_sheik]

Lowly Update:

Some more 3D printing, this time for the interior. First was the latches to hold the interior back wall hatch doors closed:




A bunch of these are needed to conceal behind the hatches and be opened with the flick of a finger:


When the rear bed is lifted up to the ceiling the area under the bed platform will have some LED "can" style lights that turn on to illuminate the dining area. I had to design and 3D print some connectors using parts from a van door that will pass electricity from a stationary frame to a vertically traveling bed frame:


I haven't hooked them up yet but they seemed to print okay:


- Sheik

 

[jaleel_da_sheik]

Lowly Update:

I designed the dining table to not only telescope up and down but to also double in size. This required a bunch of headaches as one would expect. First was milling the holes/slots for the concealed hinges. These had to be exactly aligned using a router set to different depths. 3D printer to the rescue to make clamping and router jigs:


With the two table tops aligned the router jigs were prepared for battle:


The table tops were clamped and oriented vertically, the jig located and then the two matching shallow slots were milled. Half-moon shaped inserts were plugged into the jig and the deeper slots were milled out. This process had to be repeated 4 times:


Testing revealed a very tight fit with the hinges resulting in a one-time-only installation. Removal of the hinges will require destruction of the table tops; here's to hoping that won't be necessary!

The telescoping base mounts underneath the tops. When the upper table top swings open it needs something to hold it up in the deployed, cantilevered position. The 3D printer was used to crank out some knobs with captured nuts, clamping bases and pull bars. Some all-thread and aluminum tubing completes the package. Here are a handful of pics to hopefully augment this explanation:





Yet another assembly that won't be proved out until it is installed. Fingers crossed it will work!

- Sheik

 

[jaleel_da_sheik]

Lowly Update:

A scattershot group of 3D printed components for the habitat while the cabinets get sanded and I wait for warmer temps in order to get them finished.
First is a multicolor nameplate for a couple of electrical buttons on the fresh water side of the system:


I needed to provide illumination for the license plates. Using a clear LED side marker light, I designed and 3D printed a series of housings to choke down the light to make a "spotlight" that shines onto the plates from the rearmost outrigger on the subframe:


Feet for the microwave to keep in bolted in place:


Feet for the oven to keep it bolted in place:


Screened cowling for the combined air exhaust of the dryer, shower vent fan and toilet vent fan:


The screen was printed out of flexible filament for removal and/or replacement if smaller orifice size is necessary:


Mounted to the habitat:


- Sheik

 

[jaleel_da_sheik]

Lowly Update:

More 3D printed goodies. Above the passthru between the habitat and cab is the location where air and electricity is run from one side of the truck to the other. I needed to build a cover for this area to hide the ducting and wire runs. I thought about cutting down a large PVC pipe and using its quarter-pipe as the cover but figured I could do something similar on the printer. Had to break it up into interlocking segments (the nature/limitations of printing):


Test fit into place:


Had to make several pass-thrus for electrical to enter-exit the habitat from below. These will have custom printed flexible inserts to seal the pass-thrus once the wire runs are finalized:


An air exhaust port on the back of the toilet was needed for connecting up to a flexible hose along with a gimble for passing thru the urine hose:


A flexible boot was needed for covering the electrical connection on the light that shines down on the fresh water tank to allow for visual inspection of the level:


This light will mount to a hole located in the mount bracket of the sliding toilet base:


- Sheik