Two new toys unimog 404

[joeblack5]

Spring has started so we got out and tried to remember what was on the agenda.
Decided to tackle some insulation, more as an experiment and to get back in the groove.
Then we drilled holes and screwed the skin with ss screws and 1/8" thick nylon washer of the bus framing to reduce with thermal bridging.. left the screws loose, added sicaflex 252 in the gap and tightened the screws.

 

[joeblack5]

The weather is cooperating..finally found energy to weld the remaining section of the rear wheel well and add steel to the inner skin around the rear wheel to beef things up a little. Then closed the holes in the floor.
Now we needed some moral support so moved on to interior work, just to see where we were going.
Cut another bulkhead and then the bathroom wall. Temp installed kitchen sink. Installed a bus seat for the "dinette".
Anyhow..an interior shot of the status quo.

Our daughter passed her driving exam, that is good...interest in vehicles has increased

 

[joeblack5]

More interior rough work.

Can't put the final countertop in because the rear entrance door has to be modified from dual to a single.. and that creates more space, hence a longer countertop nevertheless it shows proof of concept. Put a shelf above. Will have to make sliding plexiglass door to keep the elf on the shelf.
Made the connection from cab to bus. Drilled a lot of 1/4" holes in the angle profile that remained after I took the rear cabin wall of.. wooden 2*6 bolted in place Things are stiffening up. Laid out the table for the "dinette"
Tomorrow some work on the couch and mount angle iron to connect the bulkheads and walls to the floor and support beams.

In the mean time I got 316 stainless seamless tubing to sleeve the rear brake cylinders.. this is slightly undersized but the rubber cup seal fits fine
Is 1.25*0.065 wall. It will be nice to work a bit on the operational side. Still need to replace the turbo and install the intercooler.

 

[joeblack5]

So I made a mistake in the description above about backdoors. To avoid confusion I meant the original handicapped side doors at the passenger rear side .

 

[joeblack5]

Today was a dull and painful day.. first I had to remove the other rear brake cylinder. Then a lot under the mog to drill holes to structurally connect things together. It was all muddy and wet from the rain so I got dirty wet and tired.

But there was a very positive development.
My friend Ellis stopped by. He machined the critical transmission input shaft drive extension for the tdi motor and the more structural welding. Ellis took the wheel cylinders to sleeve them.

 

[marchplumber]

Good ole dirty, wet, and tired......happiness and joy!

 

[joeblack5]

Today we did some work on the layout again. First we supported the floor better then over to a Couch/ bed design. The plan is to make the couch 24" wide and then can be pulled out 10" while the back support folds down. Then together with the driver seat foldable to the front this will become a bed . We used some heavy duty 28" long slides and removed the thinner telescopic pieces since we only need to pull 10" out. We reinforced the remaining slider with an aluminum u profile that fitted exactly.. pure luck..less likely to deform.now.
Anyhow , first steps..

 

[joeblack5]

Yesterday we made a 2*4 against the wall to build the couch of . I was lazy and went a bit fast. Last evening I thought that structural design could have been better.
So this morning I tore it back out ,cut a hole in the bulkhead for the 2*4 . Now the forces are not carried by the screw anymore.
Mocked up the plywood seat and will test with some cushions but I think it can be a bit smaller. Younger daughter for reference..
Tomorrow I will concentrate on the second rear wheel well. It is more complicated because it interferes with the door.

 

[joeblack5]

Pretty chilly day today. On top of that I forgot to charge all my batteries. Decided to dig into the passenger side wheel well. It looks like the original wheel well can be partially reused further to the back. That would be a lot less fab work.

 

[joeblack5]

Pushing along to get this 404 for a tryout trip.. cut more floor out, removed original aluminum wheel well and reset in further back and inwards... Now the next part.

Then brought some wife made pillows in from an earlier camper build to see how height and width of the couch worked out.. to borrow I will cut 4" of the width..

Put the overhead bed in to get a feel.
For reference I am 6ft02" on a good day
Probably can lower it a bit now that I found a way to lift it up during driving.

 

[joeblack5]

I am under some pressure to get this well with me forgetting some tools.. the afternoon was better.
Back on the brakes.
Since the cab is now lifted 3" the clutch and brake pedals have to be raised. Fortunately other people have done this before so I can nicely copy. The holes are about 2-1/2 apart.. see if I have a piece of 1/4" plate around to make some reinforcement. The brake rod is going to be pretty long..
My clutch is hydraulic so I will have to modify that separately.
Finally got my head straight about the 3" spacers for the rear cab mounts.. I will reuse some body mounts with donuts from the donor bus to allow the cab some movement and vibration forgiveness.
The aluminum plate is the adapter to the Bosch hydromax brake amplifier..


Oh and see what followed me home .. a 1975 awd FWD snowplow with a 855 Cummins and 5 SPD automatic.

 

[joeblack5]

Another day, the girls walk the dog to school.. then I go and pick him up and we go to the barn where the 404 is in progress. It is nice to have the dog as company, hence he is the pics.

Here is the next experiment with the overhead bed.. put some hinges in and made some cuts so that it confirms more or less to the ceiling. I think it is going to work out good.

Then went home and started on brake stuff.
Found a 1/4" piece of stainless plate to raise the pedal group up 2.5"... would have been nicer if it was a 1/2" wider but it is what it is. By that time Tanya came home and I thought to expose her to some 1/2" drilling.. told her to keep the chips coming and add drill oil...she did not disappoint.
Not to bad for HF drills.
Then the aluminum 3 to 4 hole adapter.
When all lays in line then this is what you get, old master brake cylinder next for reference.
Not sure how long it gets . Will see when I mock it up again and see how the access to the brake reservoir is. Always can go remote but if this works then good.

 

[Mullaney]

Another day, the girls walk the dog to school.. then I go and pick him up and we go to the barn where the 404 is in progress. It is nice to have the dog as company, hence he is the pics.

Here is the next experiment with the overhead bed.. put some hinges in and made some cuts so that it confirms more or less to the ceiling. I think it is going to work out good.

Then went home and started on brake stuff.
Found a 1/4" piece of stainless plate to raise the pedal group up 2.5"... would have been nicer if it was a 1/2" wider but it is what it is. By that time Tanya came home and I thought to expose her to some 1/2" drilling.. told her to keep the chips coming and add drill oil...she did not disappoint.
Not to bad for HF drills.
Then the aluminum 3 to 4 hole adapter.
When all lays in line then this is what you get, old master brake cylinder next for reference.
Not sure how long it gets . Will see when I mock it up again and see how the access to the brake reservoir is. Always can go remote but if this works then good.

.
Absolutely!
And the best part is that the dog doesn't complain...
Just kinda kicked back, curled up and comfy.

 

[joeblack5]

Installed the pedal group, haha, clutch pedal interference with the steering shaft.
Really have to find the thread that talked about this.
Changing the angle of the steering box and cut a corner of the clutch pedal will do the trick i think.
Fitted the whole assembly to see where the brake reservoir ends up..right under the seat.. I think I will cut an access hole there with a cover plate. I could move the master brake cylinder further backward, behind the cab but I do not like all that weight hanging on the three m10 bolt that held the original master brake cylinder in there. I had Tanya put the pedal group in place

Some more fitting.. and maybe tomorrow..??