The long weekend has given me an opportunity to do some more work on the truck, to date it has been rather slow going since I went back to work, with most of the work being small jobs I can finish in an evening or weekend.
This being a four day long weekend I got time to do a bit more. I fetched the centre roof panel on Friday morning early, and then spent the rest of the day checking the wiring diagrams, fitting a few more cables into the conduits as one the roof goes in, there will be next to no chance that I can get any more wires inside. I also sorted out the last bits of insulation in the roof, to ensure that we keep the heat in or out.
After sanding, cleaning and priming the supports, it was time to bring in the panel - it just fits in from the front. About three years ago I planned to fit this panel in through the front - so it was good that it fitted. The original plan was not to have a rear window so we could put the spare tyre on the back, but early on we decided we liked the idea of having windows on all three sides of the bed, so the full width rear window went in and the spare goes on the roof.
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The "bump" in the roof is a recess I decided to fit to create a bit of extra headroom over the main walkway, Its only 50mm ( 2") but it makes a big difference, creating a nice feature as well.
Sliding it in as easy, the panel, despite being 3.3m long and 1.2m wide, it only weighs around 13kg. I used the blankets to protect the paintwork on both the truck and wood insert. Then it was a case of fitting the roof panel and holding it in place - Using the every sort of prop I have to hold it in place, the panel is finally in.
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With the interior full or props, I decide to finish the starting battery box. It has taken a long time to find a good position for it, so many thing to consider, security - a big truck battery is a nice target for thieves, - having the heavy weight of a big battery hanging off the side of a truck - the Optima 31A weighs 27kg, so the box has to be a substantial structure and have a decent strap to tie it down. I have to find a space on the chassis rail that has decent mounting points and then the normal things for a battery box, fully lined with plastic to prevent shorts, vents, drain holes in case any water gets in etc.
After making quite a few cardboard prototypes, I finally found a place for it, and got some steel bent up during the week and after spending the day at the beach yesterday, after dinner I decided to spend a few hours working on the battery box - I was making good progress, so I just carried on working - and completely lost track of time. At 2:00am I got a call from the missus, wondering where I was. I decided that it would be enough for the night.
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After the Easter Bunny has delivered the load of chocolate ( I got a quite a few myself) I decided to put the sugar high to good use and work and finished it off in a few hours. I decided to fit an isolation switch, not sure how many amps the reduction gear starter motor draws, but I fitted a 1000A Hella switch I got off fleabay for a good price. I welded a tag on the side of the box so that I can put a pin or something through the handle of the switch to keep it in place.
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This is what it looks like in position, getting the heavy battery in and out with the box in place is not easy, the thing is damn heavy. Anyone trying to steal it will need a few muscles as there is not much space, still after getting it in and out 6 or 7 times this afternoon to check the fitting etc, I know it is possible you just need to be able to curl 27kgs with one hand
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