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Discussion Starter #181 (Edited)
removing the camper from the truck

I mentioned this briefly earlier in this thread, but a recent discussion on rv.net made me a realize that maybe it's something that I should explain in a little more detail.

Other than the box vs. a cargo bed, there's no difference between my M109A3 and a regular M35A2, which is what most people recognize as a deuce and a half. The M109 box actually has skids on the bottom of it and only takes a few minutes to remove the hardware that secures the box to the chassis. Here are a couple of pictures to show how it's mounted to the chassis.







(what looks like rust is really just undercoating & crushed red cinder-rock they put on the roads in OR in the wintertime)

So part of the plan is to build a low-profile flatbed that will be sandwiched between the box and the chassis. Don't expect to drop the box often, but will be useful if/when I set up camp somewhere for an extended period of time. The trailer box will also be removable, so I'll be able to set my camper and trailer boxes down on the ground, and use my truck/trailer for other things. Have gone to a lot of trouble to design the camper box to be mostly self-contained, to make it easier to take it on/off the truck. Going to build something like oversized camper-jacks to make removing and installing the camper box easier. Greenjeepster on steelsoldiers showed me how some heavy equipment is loaded/unloaded like that, using a salt spreader as an example. Think that's what I'm going to copy, more or less.
 

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Discussion Starter #182
truck vs. motorhome

Building mah deuce to travel, and want to be able to visit some really remote places. Plan on spending a lot of time off-road, but with everything in the world that I own inside that vehicle, I'm not going to be taking too many unnecessary risks. More about getting there (and back) than taking the most challenging route. But as soon as I drop off my house, it's just a truck, and as much as I love it, it would be relatively cheap and easy to replace. So when I'm talking about building rollcages, adding lockers, modifying the suspension and adding full-hydro steering, please keep in mind that this is a truck that I plan on using in other capacities.
 

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Discussion Starter #183
rollcage

Went down to Salinas today and picked up the doors and windshield frame so I can cut down the hardtop and start taking some accurate measurements for the rollcage. Hoping to get busy on that this weekend, but am working outside so am at the mercy of the weather.
 

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Discussion Starter #184
in the event of rain

If the weather doesn't cooperate, will spend my time bringing this thread up-to-date instead. But I'd rather be working on mah deuce than writing about it.
 

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Discussion Starter #186
hardtop

Started cutting down the 900-series 5-ton hardtop to fit the new cab. Was exactly 12" too wide. Got the lower/back part of the new hardtop cut down and welded back together. Kinda like the offset rear window. Not going to matter most of the time anyway.



















 

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Discussion Starter #187
hardtop

Got all the insulation removed from the inside of the upper part of the hardtop, and will cut that down tomorrow (if it's not raining).



 

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Discussion Starter #188
hardtop & roofrack

Got the top part of the hardtop cut apart today. Took the width right out of the middle. One of the support ribs was right on a cut-line, so I removed it. Peeled it using a hammer and chisel instead of drilling out all the spot-welds. Not too concerned about the holes because I'm going to reinforce the roof by gluing a laser-cut panel on the outside. That panel will also serve as a low-profile roofrack with integrated tiedown points. Think I might also try to reinforce the roof on the inside by adding layers of insulation and fiberglass. Gotta look into how I might want to go about that.



















 

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Discussion Starter #189 (Edited)
dogs

Was really nice out today, so I stopped work early and took my dogs for a run. Gonna take a minute to introduce them because they're a big part of this whole equation. Slayton is the big red one and Lola is my little girl. They're both carolina dogs. Designed and built this motorhome with them in mind. Wanted to have enough room to live/travel with another person and my two dogs comfortably. Was pretty challenging making room for everyone and everything in a 12ft box... and then my dogs had puppies. Six of them. This was back in March of last 2010, almost exactly a year ago. Ended up keeping two of them, sort of by default. Couldn't find homes for them with friends/family, and didn't want to sell them. So my wolfpack has doubled in size and it's got me scratching my head. Honestly don't have any idea how I'm going to make this work. Will probably end up designating a large portion of the trailer as the doghouse. Seems like the obvious answer.















 

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Discussion Starter #192
fuel system

As part of that first round of maintenance, I drained the fuel, changed all the filters, and pulled the pump. The fuel filters were in pretty good shape but there was a bit of gunk and sludge in the tank and in the bottom of the filter cans. No rust though, which was a relief. Posted on steelsoldiers, asking about the best way to clean out the fuel tank, and decided to have it hot-tanked. Also had it lined with a product called Red-Kote too. Learned afterwards that I could have purchased applied something similar at home.











 

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Discussion Starter #193
fuel system

The fuel pump did have a bit of rust on it, and the guys at the radiator shop where I had the tank cleaned and lined suggested using muriatic acid. Worked great after I figured out how to neutralize it afterwards. Forgot to snap a picture of it all cleaned-up.




Also noticed that the rubber pickup hose had a hole in it where it had rubbed up against the hinge-clamp on the pump. So I replaced it and routed it carefully.

 

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Isn't it funny how those little thing drive you crazy?
Once you get them all addressed you'll think it's worth a fortune.
I rebuilt and repowered a 37 ft RV the same way about 10 years back.

Good looking dogs you have. I spent many a years camping with my Sheltie years ago. He went everywhere with me.
Keep up the good work.
If you ever come through North Central Texas and want to srop in I've got planty of room for the Rig and Dogs to run out here for a visit.

Would enjoy looking over the Deuce.
 

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Discussion Starter #195
Thanks SSSRodeo. Really appreciate the invitation and might just take you up on it. Have actually been looking into becoming a Texan. Yee-Haw!
 

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Thanks SSSRodeo. Really appreciate the invitation and might just take you up on it. Have actually been looking into becoming a Texan. Yee-Haw!
Yep, you'd like it out here. I ride Adventure Bikes too.
Got a tricked out KLR. We use to ride into Mexico a lot only the climate is not to heathy down there right now.
Here's a link to our ride last Summer.
http://www.klr650.net/forums/showthread.php?t=83156&highlight=Geezers+Dual+Sports
I'm the guy in the Neon Jacket!

One of my riding buddy has a plated XR 650 Honda that's a hoot to ride on the street.

We're North West of DFW and lots of work going on the Oil Bidness around here. A man with skills can make a living here a lot easier than other places.
But, you gotta get used to the heat. And Texas is a big place to find work and a place to fit in.

We've got plains, forest, mountains, Ocean and Hills all in one state.
And Colorado is our Official Playground!

When you come this way drop by. I've got RV hookups for two next to the Shop. Complete with a dump station!
Even got a shop big enough to fix your Deuce inside.

Curtis
 

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I've been thinking of building an M109 as a camping/expo rig for a while now. I'll have to pass this on to my father in-law that lives in Lakeview too. I'm sure he would love to do something like this for long camping trips. He might even want to drive up and take a look at yours sometime. :beer:

A lot of good ideas in here and very well put together. Thanks for the effort in sharing all of this with everyone.
 

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Discussion Starter #198
fuel system: filtration

Posted this on steelsoldiers: ultimate onboard fuel filtration / processing setup. I'm new to all this stuff, but I knew that some of the steelsoldiers members have a lot of experience dealing with WMO, WVO, and filtering/processing a variety of other fuels/fluids - so I asked them to take a look at the list of components I'd put together. Got a lot of helpful input about things like heating, magnetic filtration, what to look for in selector valves, etc.


In the spirit of using my new multifuel LDS engine to it's full potential, want to equip Mah Deuce with the ultimate fuel system. Talking about being able to pour just about anything flammable right into the fuel tank, knowing that it will be processed and filtered before it reaches the engine. Since I'm going to be living/traveling in this M109 motorhome fulltime, all the fuel processing equipment has to be built into the fuel system.

When I started researching fuel filters and related components, the name Racor kept coming up. Everything I read seemed to indicate that they set the standard when it comes to fuel filtration. So I contacted them, and they've been really enthusiastic about this project. We're calling it 'an exercise in overkill'. Although Racor has a ton of experience filtering all types of fluids, it's not often that they're asked to do it all in one system. The problem is that a lot of components (filters, seals, etc.) are made to work with one type of fluid, and are not compatible with another. But I think we've came up with this list of components, that when properly configured, would seem to be able to filter just about any type of fuel.

So here's a basic rundown of the system as I'm currently envisioning it:

There will be a total of 100 gallons of fuel capacity, split evenly between two tanks: one 50 gallon tank in the stock location on the passenger's-side, and another stock 50 gallon fuel tank on the driver's-side (where the spare tire used to be). Was planning on duplicating something like what's in the deuce and a half and 5-ton tractors, which were equipped with dual tanks and selector valves to switch between tanks. But steelsoldiers members like cranetruck changed my mind and convinced me that I should separate the diesel and alternative fuel systems. So one tank will be designated as the clean diesel tank, and the other will be designated as the 'slut-tank'.

1) Filtration will start with one of these funnel filters, which I'll use whenever I'm filling the slut-tank with fuel/oil from questionable sources.

2) Racor's Marine Turbine 1000 units will serve as the primary fuel filters (one for each system, equipped with 20-30 micron filters). These things look amazing! It's a centrifuge, a filter, and a water-separator all built into one unit. Cranetruck told me these were stock equipment on the HEMTT's.

3) Although the Turbine 1000 units are specifically designed to separate water from Diesel, Racor told me that I would need an additional water filter to separate the water from used motor oil, ATF, hydraulic fluid, and WVO. They recommended one of these filters in one of these filter housings. Evidently those have a much higher percentage of water in them, and the water is suspended in those fluids in such a way that it makes it difficult for the Turbine to separate the water from them. Only caveat is that this filter is not compatible with gasoline, so I'll have to make a bypass line that I can switch over to whenever I put gasoline through the slut tank. No problem.

4) And then these filters will be equipped with 10 and 2-micron filters, and will serve as the secondary and final filters in the system.


So what do you guys think? What would you add, or take away, or do differently? How would YOU design/build the ultimate fuel system for a deuce? The only thing to keep in mind, is that space is at a premium. This is a motorhome. I'm not trying to turn Mah Deuce into any type of dedicated fuel-truck.


Turbine 1000 (1 of 2)




FBO filter (look at the size of those fittings!)



 

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Discussion Starter #199
fuel system: filtration

Also been talking with the people at Magnom about their magnetic filters. Evidently, they're able to remove 99% of all ferrous metals from just about any type of fluids. It's not a mesh/media-type filter, so they're not rated in microns, but I was told that they can/will reliably filter down to less than 1 micron. Sounds great, right? I'm looking at the Max and the Clear 5. The Clear 5 looks like it would be a lot easier to service (clean), with it's removable bowl - but's it's also pretty spendy (about $800). Would like to use at least one of these magnetic filters, especially after reading about all the metal that's suspended in waste motor oil (WMO).
 

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Discussion Starter #200
fuel system: heating

Not exactly sure what I'm going to do about heating in the tanks. To start off, I'm just going to install one of these Racor coolant heaters in each of the fuel supply lines, before all the filters. I know that the tanks will also need to be heated in really cold weather too, so I might also drill a few holes in the top of the tanks and install some bulkhead fittings that will run engine coolant through a coiled loop of copper tubing (or maybe something like PEX tubing?). Radiant heating is being used throughout the vehicle, with multiple heat sources, so it will be very easy for me to create a dedicated loop to heat the fuel tanks (going to do something similar for the water tanks).
 
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