Sept 30: Email (pic)

Sept 30, 2007, Tasks Accomplished:

• Went to GF
• Got new vent pipe for water heater
  
• Emailed ElectroAutomotive about lack of parts, specifically the adaptor, which is now needed
  
• Uploaded pictures onto Flickr
• Installed new vent pipe on new water heater

Flickr slideshow

Uploading pictures onto the internet and emailing ElectroAutomotive about lacking parts. Wouldn't recommend doing business with them, unless you have forever to wait.

Got the new vent pipe installed on my dad's new water heater. Looks good.

The following picture is the pair of 90's I added to the pipes. The pipes had been forced into an angled connection, which finally started leaking. The connections are no longer under stress. And, if you look back at the prior pictures, you will notice that the burn marks on the joist were there before I started working on the tank (though, I have charred wood other times when sweat soldering, just not this time).

Sept 29: Water Heater (pic)

Sept 29, 2007, Tasks Accomplished:

• Replaced my dad's old water heater
  
• Relaxed, and drank a few beers with my dad

The hot water heater at my dad's house looked a little sad, and was leaking. Since I was around, might as well replace it for him.





Notice, in the following picture, that the pipes go up to a T that is leaking. The soldered connection has gone bad, as there is stress on the connection. The pipe to the right is inches above the connection to the left. This will have to be remedied.



The new connections and new valve.



Section cut out and a 90 added.



For some reason I didn't take a picture of the finished product. You can see some pictures on the next page, though.

Sept 28: Finishing Hold-down

Sept 28, 2007, Tasks Accomplished:

• Finished cutting and welding bed battery frame (with the exception of long cross pieces
• Painted top side of bed battery tray
  
• Spray painted battery hold-down
  

Flickr slideshow

Sept 27: Battery Hold-down

Sept 27, 2007, Tasks Accomplished:

• Got bolts and all-tread in GF last night
• Picked up steel in GF in the morning
• Drove
• Cut and welded on the battery hold-down frame
• Painted second coat on the bottom of the bed battery tray
• Julie picked up used shock bushings from muffler shop for bed battery all-thread rubber washers
  

Flickr slideshow

Sept 26: Two Weeks

Sept 26, 2007, Tasks Accomplished:

• Painted underside of bed battery tray
• Spray painted aluminum on bed battery tray
  
• Made, glued, and screwed four plywood corner gussets
• Started lawnmower
• Welded bird feeder hangers
• Stacked batteries in final shape and taped all positive terminals
  
• Started welding outside of bed battery hold-downs
• Went to GF for steel, bolts, etc.
  

Flickr slideshow

Sept 25: Batteries Arrive!

Sept 25, 2007, Tasks Accomplished:

• Got batteries
• Unloaded batteries
• Tested geometry for plywood bed battery tray
• Fixed geometry (batteries taper a base, who knew?)
  
• Added more bolts to battery tray, as planned
• Welded lawnmower deck
  
• Received wires (only) from ElectroAutomotive
• Caulked trim on battery tray
  

Flickr slideshow

Sept 24: Grinding and Welding

Sept 24, 2007, Tasks Accomplished:

• Finished fabricating front bed battery hold-downs
• Ground smooth edges on brackets
• Clamped brackets in position, then removed bed
  
• Sanded then welded brackets
• removed engine mounts from engine
• Cleaned engine mounts and installed on tool (wood jig)
• Leveled tool
• Painted new flange brackets
  
• Reinstalled bed
  

Flickr slideshow

Sept 23: Email (pic)

Sept 23, 2007, Tasks Accomplished:

• Went to GF for fast internet access
  
• Emailed and loaded pictures onto internet

Wow, GF looks just like Seattle today. Makes me feel homesick.

Sept 22: Battery Tray

Sept 22, 2007, Tasks Accomplished:

• Drilled all-thread holes for battery hold-downs
• Threaded and sized rear all-thread, goes through original bed to frame mounting flange.
• Drilled front all-thread holes
• Drilled and rough-cut frame flanges for front two bed battery hold-down

Flickr slideshow

Sept 21: Starting Battery Tray

Sept 21, 2007, Tasks Accomplished:

• Installed bed mat
• Cut plywood for bed battery tray
• Cut, drilled, and installed aluminum battery edging
• Talked about tires, should get estimate on Monday
• Moved truck around (to access bed)
  
• Bought bolts for battery hold-downs
  

Flickr slideshow

Sept 20: Motor Arrives

Sept 20, 2007, Tasks Accomplished:

• Got more insulation glue
• Got taillight wiring connector
• Glued rest of under bed insulation
• Put bed on
• Wired taillights
  
• Picked up motor and controller
• Emailed ElectroAutomotive about parts
• Bought rubber bed mat
• Bought new multimeter
  

Flickr slideshow

Sept 19: Insulation

Sept 19, 2007, Tasks Accomplished:

• Bought 2" foam insulation, plywood, screws, 2x4's, expanding spray foam, foam glue
• Cut and formed under-bed insulation
• Glued Some insulation
• Glued heater box
• Glued pads for frame to bed box
• Removed interior carpet
  
• Talked to motor shipper, motor arrives tomorrow
  

Flickr slideshow

Sept 18: Bed Work

Sept 18, 2007, Tasks Accomplished:

• Final coat of paint on interior of bed
• Removed and dissembled heater box
• Bought 2 new 110VAC 1500W ceramic heaters
• Dissembled heaters and modified heater core for electric heat
• Installed rear brakes
• RTV'd underside of bed
• Measured insulation for underside of bed
  

Flickr slideshow

Sept 17: Bed Work

Sept 17, 2007, Tasks Accomplished:

• Ordered rear brakes
• Bought bolt for rear shock and installed
• Sanded and painted inside of bed
• Straightened dents out of bed
  
• Painted 12V battery tray
• Removed seats
• Removed bottom of dash
• Removed heater core
• Painted tailgate
• Sealed holes in bed with RTV silicone

Flickr slideshow

Sept 16: Start Rear Suspension

Sept 16, 2007, Tasks Accomplished:

• Jacked up and blocked rear end
• Removed, pounded, and reinstalled rear bumper
• Added helper leaf
• Replaced rear shocks
• Removed tires and drums, inspected brakes, decided to replace rear brakes
• Front brakes are good

Flickr slideshow

Sept 15: Drove to Great Falls

Sept 15, 2007, Tasks Accomplished:

• Drove to Great Falls (GF), the closest city with a decent selection of parts
  
• Got shocks and new spring leaf
• Got more engine cleaner
• Got hand goop
  

Sept 14: Cleaning

Sept 14, 2007, Tasks Accomplished:

• Removed remainder of fuel lines
• removed heat shields under cab
• removed electrical coil and wiring
• Removed battery to starter wiring
• Soaped and powerwashed frame and engine compartment
• Powerwashed bed

Flickr slideshow

Sept 13: Engine Out

Sept 13, 2007, Tasks Accomplished:

• Head pipe removed
• Transmission mounting removed
• Frame crossmember removed
• Clutch slave disconnected
• Driveshaft removed
• Engine/transmission pulled
• Cleaned engine with degreaser
• Built cradle-jig for engine/transmission
• Separated engine from transmission
  

Flickr slideshow

Sept 12: Starting Work (pic)

Sept 12, 2007, Tasks Accomplished:

• Disconnected power steering pump from engine
• Disconnected AC pump from engine
• Disconnected wire loom from engine and transmission
• Drained oil and coolant
• Removed radiator
• Removed intake system
• Removed fuel tank and some fuel lines
• Disconnected coil
• Removed belts
• Removed gas tank
• Removed muffler and catalytic converter

Flickr slideshow

First day of work! The following pictures cronical the initial day of the ICE component removal.

Sept 11: Seattle to Montana (pic)

Left Seattle to drive to Montana in my little 1970 BMW that I got from a friend's horse pasture a few years ago. It had been sitting in the pasture for fourteen years, a home for feral cats, rats, and marmots. We'll see if I make it.



The car this summer, looking better.