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The adhesive has held up perfectly, much like windshield adhesive, if you use the correct product for the job, it will last a lifetime. I'm glad I made the frame and aluminum exoskeleton, we commonly use it to push brush and thigh sized limbs out of our way as we crawl through narrow wooded...

Yes, the 207 primer goes a long way, It seems as thin as water and black as night - Make a felt pad brush and it's 110% good enough in one pass. I probably went through 3 or 4 of the small 100ml bottles, but half of that was likely due to evaporation/waste. Our Ceiling Fan lid is the highest...

Whoops... Sorry for the late replies everyone... No, they normally deal with large commercial customers, the hassles of dealing with tire kicking consumers wasn't what they wanted. The same way, Sikaflex 207 and then 252 an Aluminum plate/bar to the wall, with machined holes to fasten the...

Your results may vary of course depending on your surface prep. I don't mean to alarm you, but it's worth a quick test.

We did, Sika 206 and 207 - my tests showed the Sika 252 peeled right off without it.

Thanks, Jack - You’re one of the good ones! Thanks! Thanks!! Are you saying we’re not cute? That cushion video was terrible… If you watch again you can see me getting frustrated trying to run the camera, stay in frame, remember what I was trying to say and appear to know what I’m talking...

Next, I had the aluminum step boxes CNC cut and we welded them up, And while in the garage I could dry fit them, but I couldn't install them permanently because the whole thing would no longer fit out of our garage door. I barely had room to move around let alone do anything productive. I had to...

Next, we installed the Honeycomb Composite panels, I can not recommend any manufactures, sorry. All mating surfaces were scuffed, primed with Sika 206 and then bonded using SikaFlex 252. We used small strips of a stiff rubber gasket material with 2 sided adhesive to act as a 1mm spacer so...

Next Step, Building the Exoskeleton. The angles where all CNC cut and bent to the angles required and we started welding it up! The Video shows this much better than I can with photos: https://www.youtube.com/watch?v=vLkxmSkcLvQ

Thanks! I drew a bulk of the CAD myself, although I had help from several ME friends who work in the industry. I did get ahold of the CAD model from Ford, but it was 8 gigs and when opened it brought my high-end system to it's knees. So I just used the body panels you can see there and omitted...

Phil, Where did you source your mirrors? I've been keeping my eye out for a set that's not too expensive. Not sure how good the cheap China knockoff ones are compared to OEM.

If you're inferring that the tires rub the springs, they do not. The Class 5 Trucks have a Wide Trac front axle to improve the turn radius. IIRC the smaller trucks have a track width of 68" and the 450/550's are 75" wide. This wider axle allows for greater steering angle. I can turn lock to lock...

It was at this time I started filming and putting up some videos on YouTube. I machined solid aluminum bushings and slid them into the 3/16 2x2 frame to keep the bolts from crushing the tube. The 2x2 subframe was all welded with the spoolgun to keep the warping and heat affected zones to a...

This was about the time I started CADing up the design. The aluminum subframe of the box is isolated from the steel truck frame with UHMW chain guides, trimmed to clear cross members and drilled to make room for the rivets. The Aluminum subframe is held to the truck using an original yet...

Clean Frame after Degreasing and Acid Etch. Then we POR15'ed the frame. It would have been the ideal time to upgrade the springs, but the budget didn't allow it at the time. We replaced the steel tank which had recently sprung a leak with a new XLHDPE tank from Titan Fuel Tanks. I...

The 7.3 was in fine shape with only ~150km on the dial, But we had the Motor and Trans rebuilt anyway, I figured I may as well start with a good base. We ordered Rickson Wheels with MPT81's to convert the dualies to super singles. Then with the help of good friends, We stripped the...

Hello all, As you can see, we've been lurking around here since Oct 2012, planning, saving and working towards our Overlander. In early 2013 we found the exact truck we were looking for and snapped it up. As you could see it had quite the appendage on it at the time. I started filming odds...

Scratch built from the ground up, Chassis is as close as I could get to the Turtle V, 2003 F550, 7.3, ZF6, Custom body kit to tuck MPT81's without a lift. I designed the box myself, All CNC cut and bent TIG Welded Aluminum, Composite Panel walls. I chronicled the build on our YouTube channel...

We use the ElectroDacus Lithium BMS in our rig and recommend it highly.

Cool! I'm going to need some help on my turtle!