Another Day - Another Dollar

Sure is another dollar!! The exchange rate has dropped about 45% for the Aus. dollar with all this financial nonsense happening at the moment - and it hasn't finished yet!

So part of the day was spent machining up a sample of a scaffolding "screw-jack" that a customer wanted. As he wanted about 275 of them and they can be done with only minimal attendance I thought I had better try and recoup some of the overseas buying power we in Aus. have been losing of late. They look like this.


















So - quote done - back to the business at hand. Windows go in here (some on the other side as well). Made by a Dometic Company called Seitz - sounds German to me - nevertheless they seem to be the ones to have. Being made overseas I figure I better buy some from local stock now before the devaluation takes effect on new stock. Three suppliers in Aus. - and they don't all stock the same sizes so it's a complicated calculation on freight and availability to find out what's the most economical way to buy. In the end they all come from the other side of Australia with about A$200 in freight to get them here! That's the trouble with living in the most remote capital city in the world....


















OK Back out into the workshop and fit up the front mount which was welded yesterday and had to wait for it to cool. My newish neighbour (who owns a welding company), it turns out is a welding inspector, and has been looking at my welding for some time. He tells me it is up to standard and will certify me to do my own welding - life is full of surprises. So I welded up the front mount yesterday and of course because I want it to be really good it looks awful (to me anyway). It's structurally OK - just looks a bit messy. It looks better today than it did yesterday - I hope it looks even better tomorrow! Temporarily fitted in place again. Can't do the rear mounts today as I do not have the finished U-bolts I ordered (I don't want to drill holes for them until I have measured them after my experiences in trying to get them made the other day.)






















So back to the rear of the chassis - to weld in the bracing extensions. Pre-paint with anti-rust on the inside face and fit it while it's wet - hopefully to keep some corrosion out. Now that welding looks better!! First one side and then :


















the other. Clean up and another coat of anti-rust. This paint is magic. I have used it for years. I first tried it on a farm (I used to have) in the South West of W.A. when I dragged some old cast iron gates out of a rubbish heap where I found them when I first bought the farm. A bit of a wire brush and paint with "Killrust" gloss. These gates were then hung and still looked as good as the day I painted them when I sold the farm years later.


















and another day is gone...

Everything Takes a Day

Somewhere in another place I read a comment by someone else building an expedition camper commenting on "the time it takes". He said "Everything Takes a Day!" Even if it's a small job you think will only take an hour or so - it takes a day. I think it was Cyril Northcote Parkinson who said "Work expands to fill the time available". Sure sounds right to me.

After the weekend flu (still with me) I decided to order some U-bolts (at $10 each) just so I can make some progress. If I need to I will replace them later with higher quality. There is an hour gone on the phone/fax etc.

After staring at the mounts for some time (I think it's called procrastinating) I suddenly realised that by reversing the use of inboard and outboard sections with regard to chassis and load I could make a much better arrangement for the front mount. So back on the mill and make another set of arms. Another hour or so.














Now the U-bolt arrangement doesn't quite fit with the base plate material. Lightbulb! Use two separate pieces for the base - drill out some rivets in the chassis and replace them with bolts which can hold the mounts as well. Much better than the U-bolts . . . I just ordered !! And of course the material required is the one size I don't have in the rack. Off to the supplier - fortunately local but still 1/2 an hour turnaround - cut and drill, drill out the rivets in the chassis etc. there's another hour.

















Get bolts, hardened washers, nyloc nuts etc. etc. another 1/2 hour.























While out take the opportunity to pick up replacement fittings for the diffs, transfer-case and gearbox breathers. They are of course all different. The original is lying on the transfer case. Works with a small spring and a rubber valve. Almost guaranteed to suck in water in a deep water crossing. The water cools the diff and creates a negative pressure and if the valve goes under water - Hey Presto - cases full of water. So a fitting and tube is used to take all the breathers to a manifold on the cab well above the chassis and terminated with an in-line fuel filter to keep out all the bugs, dust and water etc.




















While delving around the gearbox I discovered this little item hiding away. It's a fitting to enable greasing of the clutch release thrust bearing - and completely not sealed - so scrabble around on the floor to discover the bell housing has a "drain hole" in the bottom. SO apparently it's OK for the clutch to fill up with water either through the grease fitting entry or the drain hole and it will all drain out later . . . Oh Yeah!!! I can see the thrust bearing dealing with that over time. I think that one goes on the spares list.


















And that's the day gone . . Everything takes a day. . . .

I NEVER Get the Flu

Well I did this weekend. Of course it's always the weekend when you get ill... Wait a minute - I'm retired - there is no such thing as a weekend !!

I feel better already. Well enough to start updating the model to make sure all the bits will fit in the new layout.

Part of the rationale is that the body must lift off and sit flat on it's base so that it can be slid into a container. The other part is that it must contain all the essential equipment within the body so that it can be lived in if the truck needs to be elsewhere - extended repairs etc.

So - the basic three point mount.















On top of which we put some main beams for longitudinal strength and some additional cross-beams where we need to carry some substantial weight.















Then we add all the underfloor equipment - black, grey and fresh water tanks; water pump; generator and control panel and batteries.















Then we add some furniture: seats and table; the bed slides up and down over the seats and table (electric motor drive) so it doesn't have to be packed up each day. Just press the button and it slides up into the roof allowing plenty of room to sit underneath. The stairway folds down from the doorway (it is an extra security door when folded up). Some interior walls and the gas bottles - the box above holds the instantaneous gas hot water system which has to be vented to the outside. The "Webasto" oil fired interior heater goes in here as well and hot air ducted to where required.















The white walls are the ablutions area; full size shower, basin and vacuum-flush toilet. Kitchen benches, stove top and sink. Fridges are two 40litre under counter top loading Engels (can't see them here).















Some of the insulation; 30mm styrofoam (unless I can find some cheap polyurethane somewhere) all round except for ceiling which will get 50mm. If you have -10deg C. outside and you are trying to maintain 20+deg C inside you need all the insulation you can get. Similarly 60+deg C in the Aus. sun is easy! Air conditioner is a split system mounted underfloor and ducted to where it's required.















All the walls and roof in place. Just need to position the windows (Seitz double glazed) and I think it all fits !!

Out With the Old - In With the New

Yesterday I'd just as soon forget.

I can't believe how frustrating it can sometimes be trying to do what I think should be simple. (Maybe retirement turns you into a "grumpy old man" !) I need some "U-bolts" to fasten down the "torsion free mounts" (TFMs). Simple! Advertised everywhere! Everyone makes them!

First stop at "Trailer Parts" - they are generally pretty good with all sorts of parts for trailers and good prices too.

"What size do you want them?"
"16mm Grade 4.6 rod, 75mm between the legs, 275mm inside leg length, min. 60mm of M16 x 1.5mm pitch rolled thread if possible."
"Do they have to be 16mm rod? How about 12mm? Can they be narrower/wider/longer? etc. etc.?"
"Umm... I would really like them as I described."
"Don't have any like that mate. But we can make them. Take about three days."
"OK. I'll just do a bit more checking around and if I can't buy them I'll be back."

Maybe I'll try WA Suspension Specialists . .
"What size do you want them?"
"16mm Grade 4.6 rod, 75mm between the legs, 275mm inside leg length, min. 60mm of M16 x 1.5mm pitch rolled thread if possible."
"Nah! Mate! If you want rolled thread will have to be 5/8in UNF and the minimum thread length is 200mm. We either use 70mm clearance or 3in between the legs."
"OK. I'll just do a bit more checking around and if I can't buy them I'll be back."

Repeat as many times as you like it's the same wherever you go!

Back to Trailer Parts - at least they can make them.
"Hi Again! Back for the U-bolts we discussed"
"Yeah! G'day. I'll tell you what mate - why don't you go over to WA Suspension Specialists direct. We'd only order them from there anyway."

F@$%!!! F@$%!!! F@$%!!! F@$%!!! F@$%!!!

OK I'll make them myself!!

Repeat the same story for Trailer Landing Legs!! (and just about anything else you want to name!)

Better ring the customer who wanted the "blower mounts". They are all done so he can come and get them. (We only do ex-factory : arrange your own pickup. There is a a whole saga in itself related to deliveries!)
"Great. We need those - I'll be right over." (They are only about 5km away.)
So here they are two days later - still waiting for pickup! Urgent! Right!



















OK. Calm Down. Deep Breathing. Do something you enjoy. Get out the grinder and attack the truck chassis!! Out with the old rear cross member/ tow bar etc. Trim the new chassis reinforcement rails to fit.














Fitted in place ready to weld.













Trial fit of the new rear cross-member. (I've been thinking of dropping it in the mill and engraving "Expedition Adventure" through it instead of just boring round holes like the others. But then I've got better things to do - like make U-bolts and landing legs!)

Paying the Piper

Today was one of those days where the bills had to be payed. Fortunately the items the customer wanted didn't take much input as they had been done many times before and each item runs for about 28 mins in the CNC lathe so I only had to pay attention every now and then. (I know I'm supposed to be retired but it helps to keep the overheads in check and only takes about 2-3 days per month).

The sheetmetal guys called and said the pieces for chassis reinforcement had been pressed up so I dashed out while one job was running and picked them up. Trial fit into the chassis and I was very happy :)) Nice neat fit !! The end now has to be cut back at 60deg. to match the original piece (you can see the diagonal line on the chassis top right to bottom left) and then welded (to AS1554 - certified of course) and then the holes drilled for the rear mount plate. Has to be done this way to move the stress concentration out of the mount area.














Trial clamp up of the bolting bracket required to take up for-and-aft forces. Will also have two x 16mm hi-tensile "U-bolts" to take up all other forces. There is an intermediate horizontal plate missing between the two parts in this photo.














The front mount also had it's horizontal component added while I still try and figure out where to put the U-bolts. Side plates not needed here thank goodness as I couldn't find a spot for them anyhow.














Updated the "General Arrangement" drawing just so I know what all the measurements are - and now I'll have to try and rearrange the 3D model drawing to accomodate the real mounting positions.












Guess I better go arrange for the U-bolts now I know what size and how many!

Sun Tzu's Revenge

I think that Sun Tzu said something like "No plan survives contact with the enemy".

That's what it feels like at times. Careful inspection of the chassis revealed no suitable way of getting the front mount down near the centreline. This is necessary for the four point mounting to operate properly. So back to the three point mounting. With this one there is not as much need to have the centreline of the mounts on the same axis as the twisting occurs. Desirable but not as critical - especially with the type of hardware selected as it has some compliance in all axes.














Trial mounting of (unfinished) mounts to make sure everything can actually be attached in that position. Front longitudinal mount about 450mm behind front edge of accomodation unit intended position.















Rear transverse mountings (also unfinished) in approximate position. The blue beam indicates how far the acomodation unit will overhang the end of the chassis.

Baby Steps . . . Baby Steps

I seem to have done so much rushing around just looking for things. With the tray off I have been able to get a good look at the chassis and determine if what I had "planned" to do is actually possible! So easy bits first - spare wheel carrier out - the wheels/tyres are just too big to store in the conventional manner under the chassis - so the spare will have to go somewhere else.















The front part of the chassis looks rather busy! And the top of the "round fuel tank (far side) protrudes above the chassis about 75 mm. The tank can be dropped with a bit of work but it is only 160litres nominal capacity and for some weird reason the filler cap is about 1/4 of the way down the side so it can only be filled to about 120litres. Not really the range I was thinking of. The service manager at the local Isuzu dealer says the filter just in front of the tank which consists of three elements including a water trap is obsolete and can be replaced by a much more compact and efficient unit which can be mounted (relatively) remotely. That will give an extra 200mm for tank length.















The Front-Middle looks a bit clearer. But the fuel tank is quite close to the rear wheel and then the stupid exhaust is jammed in between. So round tank to go! ADR (Australian Design Rules) say the exhaust must go to the right or right-rear as far as practicable so move the exhaust muffler/silencer and pipe to wherever is convenient when the time comes. This side is fairly clear and a large rectangular tank could go in there either as a replacement or supplement. Could total about 500litres if I really try.















The Middle-Rear has a bit of space too. Should be able to put the centre "torsion mount" in there without too much trouble.














The Rear is now quite open with the spare out. The rear torsion mount will go wherever I want with no trouble at all.
















After fiddling around with the chassis a bit the conclusion was reached that the original components for the torsion mount while theoretically adequate for the job just looked a bit "weak-kneed". So - New - Bigger - Stronger in every way. The original is on the left (5mm plate) and the replacement on the right (8mm plate).

I Thought I Had a Project !!

Some people really are ambitious. While researching final painting / finishing options I came across this project. This is what it takes when you have eleven ( yes 11 ) children to take camping!

That roof has been lifted and the whole bus re-clad in 3mm Aluminium (about $10,000 in raw materials)
























Entry into the "kitchen area".























From the front looking through the lounge (double sided slide out) into the kitchen.























Rear storage area























Another view of storage lower floor rear.


















Upstairs dormitory. The black box is the main watertank (Yes . . upstairs!! All 2500kg!!) which doubles as a bed base.























Upstairs looking forward from the water tank.

This Doesn't Look Good . . .

or maybe "Trouble is manifold"?

Now that the tray is off it is all too easy to see into the engine spaces. That black discolouration doesn't look good - and that motor hasn't been worked on for 16 years (a good and a bad thing) so I suspect that getting those rusty nuts off won't be fun.

I know that when I made the decision to find a good second-hand vehicle I mentally put aside a certain budget to get everything ship-shape but it's amazing how reluctant I become when it's time to part with the money.

So now it's time to get on with it. New fuel tank to increase range. Reroute exhaust to clear new fuel tank. Get some "C" sections made to reinforce chassis mounting points. Find a PTO and hydraulic pump to drive a winch. Find a winch. etc. etc. The list is starting to grow!

Prognosis . . . Depression

A sequence of events :

. Visit to the Isuzu Truck Distributor : (conversation goes a bit like this)
"Can I put Super Single Tyres/Wheels on this truck?"
"No Worries Mate! We do it all the time!"
"Could you sell me a new truck with these tyres?"
"Sure Mate. We did 5 of them last week!"

. Visit to the tyre dealer :
"I want to order 5 new Super singles and rims to go on that truck."
"No Worries Mate! We do it all the time!"
"They cost HOW much?? Oh OK. Do it anyway."

. Fit the tyres - I love those tyres - the truck is SO much nicer!

. Engineer arrives - explain the torsion free frame :
"No Worries Mate! It'll work great. So - how did you get compliance for the tyres?"
"I haven't yet. I was going to do it all at once with the Motorhome inspection."
"OK. What size were the originals - what size are these? WHAT size are these??? No chance mate - can't be done!"

. Ring the Isuzu Distributor
"About these Super Singles - where to I get them inspected?"
"Bring it in here Mate. We are certified to do our own inspections."
"and you'll give me a compliance certificate???"
"DUH! You'll have to get that from an engineer"
"So what do you guys do?"
"We make sure it complies with the compliance plate he issues."
"So do you get compliance plates for all these type of tyres you fit?"
" Nah Mate. We don't bother for them. Everybody does it'"
"Do you know that everyone of those vehicles does not comply, can be put off the road with a red sticker and that ALL insurance is null and void?"

CLICK . . . BUZZZZZ ......

Hmmmm....

OK Find "the" engineer certified for Heavy Truck Modifications. Somehow I know what's coming! Really nice guy - tried to break it as gently as possible..

Somebody (!!) has to analyze
. Braking with larger moment arm due to increased rolling radius,
. Suspension dynamics with increased unsprung weight,
. Steering geometry affected by lack of convergence of "king pin inclination", castor angle etc.
. Increased forces within the steering elements (especially with uneven braking),
. Changes in stability due to changes in chassis height, track width, overall width,
. etc., etc., etc..

Isuzu has in all previous cases declined to participate - and no-one around really has the equipment etc.

"Hello. Is that the truck wrecker? Can I please buy my old wheels and tyres back?"

You Need a Little Operation

The tray really needed to come off. There were too many assumptions and approximations beginning to accumulate. I needed to get in there and measure and poke and prod! So - off to the wreckers for an operation. Lift the tray off - set up some new lights on a temporary bar and back home again. Really quite painless considering I was able to sell the tray and the old tyres for a few hundred dollars. The tray had a wooden floor so it it's not a highly desirable item!! Ring the engineer and arrange for a visit tomorrow so we can deal with the mounts for the torsion free frame.

Suz - ready for her operation



















The "Trayectomy"




















Post-op Patient

Millimetre by millimetre

Doesn't quite have the "punch" of "inch by inch" does it?

Well today I had to do things to pay the bills so nothing was done on the physical construction. However while working away I was able to think about the necessary elements of the camper mounting. Although the principles were OK I decided I had a few details sort of "back-to-front" and was able subsequently to sort them out and be much happier with the arrangement.

Although the principles have been worked out some of the precise measurements will require dismounting the existing tray from the chassis. This led to a small conundrum as I didn't want to have to remount it in order to be able to fetch the materials I would then require. A neighbour dropping by for a chat fortunately solved that by offering the use of his truck for the fetching and carrying. (Thank you Art!)

So after work this evening I sat down to update my current 3D model to see if I would be happy with today's ideas. Below are the result (in somewhat primitive form until the actual measurements are taken but nonetheless reasonably accurate). I think it will work OK.

The next step is to place longitudinal beams and floor bearers much of which will depend on the position of the auxiliary equipment and fittings. I plan to have an underfloor storage area approximately 300mm deep throughout as I will make use of the full length of standard size sheets (of whatever I cover it with) which are 2400mm high. With insulation that should allow for approximately 2050mm headroom.

So this is the basic torsion free mounting:













With any luck this weekend I will remove the old tray and start the real work.

Big Wheel Ballet

The Nutcracker's Suite

The following is not an endorsement for a particular brand but for the concept of the item. While fortunately my trip across Aus. was completely trouble free in bringing Suz home it could have been completely different.

When I decided to change the wheels and tyres on my truck I of course had to remove the old ones! Never having had to do my own maintenance on trucks before I am beginning to appreciate just what is involved. Having also been for a few gentle test drives on local forest trails I am also becoming apprehensive about what will be involved in freeing an 11T truck from being bogged or stuck somewhere without outside assistance. It is making me very cautious at the moment.

However to continue:

When I came to undo the nuts holding the wheels on I optimistically selected the spanner and wheel brace supplied and entered into the task. Some hour later with an extension bar of approximately two metres and two people literally jumping on the end of it - I had not even loosened one nut. I dread to think what would have happened with a puncture crossing the Nullabor.

Eventually I had to drive to the local truck depot and borrow a very large impact driver to "rattle off" all the nuts and then do them up again. I don't think they had been off since new and some minor corrosion had frozen them in place. An hour or so cleaning and polishing and some anti-seize and all was well and good.

The other item which caused some concern was when I helped the local depot fit the tyres to the new rims. We did this all with hand tools so that I would learn both "how" and in fact that it "could be" done in an emergency. When inflating the tyres to the recommended pressures for the load to be carried (at the moment they are running at reduced pressure as I am not carrying any load and they would be impossibly hard at full pressure) it was discovered that their compressor would not fully inflate the tyres to their 820 kpa. for full load. (These tyres actually have greater load and speed capability than the original duals!)

I was already intending to fit a fairly substantial compressor to the vehicle to assist is various tasks ( tyre inflation after travelling over 4WD tracks and I love air-spanners and pressure washers etc..) but these experiences were causing me to reassess my ideas of what was required!

Then I found this item:














It's called a torque multiplier (and I hope it's use is obvious). This one multiplies approx. 70 times. So fitted to the wheel nuts - turning the handle is "childs play"! I have tried it on my truck and it's a breeze (despite being another very low quality Chinese import it does work) and about 20% of the cost of the big, heavy expensive impact driver I was preparing to purchase and carry.

Let's not get twisted out of shape

Torsion Free Mounts ...

I have eagerly followed all the postings in Expedition Trucks etc. that I can find and read all the info. available on Unicat, Bi-Mobil etc with regard to "torsion free mounting" and decided it was absolutely necessary to employ this technique! If you need convincing just watch the chassis/body displacement in any of the action videos for these types of vehicles.

As an aside again - I enquired of the builder of a "professionally" locally built motorhome body - on an 18T 4WD Mercedes chassis what type of mounting system they used. I was informed that the chassis was exceptionally strong and didn't need this type of mounting! Somebody is in for a $435,000 disappointment!

In our local system this will again need engineering certification and licensing authority approval so - once more into the regulations.



















An additional section suggests that when the mounting does not distribute the load evenly along the chassis rails, as is the case with this type of mounting, then the main mounting points should be as close to the rear suspension as practicable.

I have only seen one mention of four-point mounting in the discussion groups previously and thought it might be a little too complicated, but on further reflection I believe it has the following advantages :
1) The lateral mounting points directly in line with the rear wheels may allow the body to be mounted lower as room only needs to allowed for suspension movement, body movement will be restrained at this point.
2) Four points allow the body to be constructed without needing to be quite so strong as it is supported at three points along its length (3 point construction only supports at two places longitudinally).

The following photos show the essential components chosen to effect this type of construction. These pieces will make one of the four mounting points. They were selected from the central pivot point of a "walking beam" suspension system for a 30T trailer. As the body for Suz can weigh no more than 6.5T and there will be four of them - I think they will do the job, however they will need the inevitable "engineering compliance certificate".
Disassembled - note the 300mm rule in the foreground. The ground bolt is 50.8mm diam. and 220mm long.
















Partially assembled - the centre section will be attached to the chassis and the outer two sections to the body when fully assembled.















Another interesting aside...
My last business was as a manufacturer of components just like this. In fact I made these sleeves which go over the rubber cones as these pieces are normally part of the truck/trailer suspension brackets and would be convoluted castings suitable for a particular vehicle.

I did NOT make the ground bolt which cost $36 (imported from China) or the rubber cones $6 (again imported from China) - it's one of the reasons I decided to retire.