Hackney Fuso Route, Data & Service Log

Start Date: 04 June, 2007        Report Date: 4 August, 2008

Route Data

Start Date: 04 June, 2007        Report Date: 8 September, 2008

Route:

• Distance to date: ~19,450 miles / 31,302 kilometers
• Days to date: 427
• Nights in camper: ~387
• Roads: mix of freeway, two lane paved, unpaved, gravel, dirt, rock, two-track, non-maintained, flat and mountains, grades > 16%.
• Temps: 14.5F / -9.7C to >110 F / 43.3 C
• Elevation: sea level to >16k feet / 4,877 meters

Performance and Efficiency:

• Deepest water crossing: ~ 46 inches / 116.84cm - 1.168m high
• Chassis cumulative averages:
  • Miles per gallon: 9.97
  • Kilometers per liter: 4.24
  • Liters per 100 Kilometers: 23.63
• LP / Propane duration: 4 to 8 weeks depending on utilization
• Black tank capacity: 12 to 15 days, 100% utilization
• Fresh water capacity: 2 to 4 weeks depending on utilization (Estimated, this has not been tested with any rigor or accuracy. We have ~75 gallons fresh water tank capacity and have never come close to using it all, but have not been away from sources of fresh water longer than 7-10 days.)
• Genset hours: 287

Reliability / Repair / Maintenance:

• Custom fabrication  and components failures / defects:
  • raw water tank corner seam weld split three times (flawed design and construction), modified and repaired
  • raw water tank corner seams reinforced with lap joint overlay
  • raw water tank lower mount strap / bracket hanger corners reinforced (original and replacement bracket both broke)
  • repaired/rebuilt cab to camper lanyards several times
  • exhaust pipe hanger failure, both hangers, bush repaired
  • added two anchor screws to upper end of TV/DVD mount
  • corrected wiring for raw water pump cycle relays (prevents freezing of lines at low temperatures)
• Custom lighting, electronics and electrical systems failures / defects:
  • installed two relays for auto genset start controller (custom interface design flaw)
  • genset overheated when ambient temp > ~90˚ F / 32.2˚ C, three additional cooling fans added to genset compartment to solve problems
  • house bank batteries incorrectly wired, rewired and corrected problem
• Custom water system failures / defects:
  • slow drip on direct gravity fill for camper tank if overfilled (custom connection design and construction flaw)
  • added pump cycle relays/circuit for transfer pump (prevents freezing of lines at low temperatures)
• Custom LP / Propane system failures / defects:
  • tightened two joint connections due to slow leaks
  • disassembled and reinstalled float pivot assembly for tank level gauge sender - was stuck
  • leaking tank output solenoid, replaced under warranty
• Custom compressed air system failures / defects:
  • compressor has limited output capacity at elevations > 9,000 feet
  • tightened four joint connections due to slow leaks
  • one cracked brass T connector replaced
• Custom sewage macerator system failures / defects:
  • zero (0)
• Bigfoot camper structural failures / defects:
  • zero (0)
  • replaced ceiling fiberglass insulation between forward bulkhead and front cap due to condensation in very high ambient humidity environment
• Bigfoot camper component failures / defects:
  • cooling unit failure on Dometic refrigerator, replaced under warranty
  • screen door latch failure (day 112)
• Bigfoot trim and decorative failures / defects:
  •  rear step non-skid adhesive failed (separated) and replaced
• Bigfoot camper and components maintenance:
  • tighten Phillips screw that holds the bathroom vent handle (twice)
  • tightened allen set screw that holds the bathroom faucet on
• Bigfoot dealer installed options flaws / defects:
  • dealer did not seal vent installed above berth - field repair, sealed with 3M 5200
• Mitsubishi Fuso FG 140 failures / defects:
  • zero (0)
• Mitsubishi Fuso FG 140 maintenance / repair summary (see service log for details):
  • five (5) oil and filer change, chassis lubrication
  • two (2) air cleaner change
  • one (1) transfer case and axle lubricant change
  • one (1) four wheel alignment (required after installation of custom springs)
  • two (2) flat tires, both caused by road debris
  • one (1) tire rotation

Systems Utilization:

• Water filtration (100%)
• LP/Propane (100%)
• Inverter (100%)
• Shore power / surge protector - often in the U.S. due to use of retail and state campgrounds when making passages, zero for shore power in South America, 100% for genset operation
• Genset - daily if dry/wild camping, zero otherwise
• TV/DVD - 4 June to 14 September, 2007 < 3 hours, current total hours less than 20
• Camper stereo - nearly zero, very rare operation
• Cab iPod / stereo - ~50% while in U.S., mostly for listening to books on CD, less than 10% of the time in South America
• Tools - minimal in U.S. test, have used about every class of tool in South America doing maintenance and field repairs
• Spares & repair parts/supplies - nearly zero, no failures on U.S. test, usual consumables and some adapted for bush repairs in South America
• Grill - nearly every day in U.S., minimal to moderate in South America depending on location
• Microwave - once or twice a day, mostly use the timer for coffee press and tea timer, use to warm and cook food in South America
• Data array & electronics - 100% if I'm working on a project, occasional otherwise
• Motorcycles - rare for stops of 1-3 days, essential mobility & exploration tools for longer stays, have used in every mode except road scouting

Systems / Items added since departure:

• Wireless external and internal thermometer in cab and camper. Replaced first set with a unit including a low temp alarm.
• Coat hooks in camper
• Rolling shade for vent over berth
• Velcro wire wraps for laptop power supply under dinette table
• Dual Rear Wheel (DRW) valve stem extensions. Removed both sets in South America due to failure of one in Patagonia, could not risk losing air pressure.
• Folding rear view mirrors on the bikes
• Battery monitor/chargers for the bikes
• Clips to hold berth storage lids open
• Net for toilet paper storage in bathroom
• Jumper cables for bikes (on-bike system)

Major operational discoveries / characteristics:

• On and off-road handling was dramatically improved by custom springs, aftermarket shocks and pivot frame shocks
• The vehicle is capable of doing more off-road than we will probably ever ask of it in a non-emergency situation
• At altitudes over 5,000 feet and temperatures over 85 F on steep or extended grades chassis engine overheating can be an issue
• At altitudes over 14,000 feet the engine will only pull to about 2,200-2,400 RPM
• The chassis is very road-crown sensitive. It will pull to the downhill side on either slope. Four wheel alignment has been done, with no improvement or change in this characteristic. 4/14/2008 note: This characteristic has greatly lessened and is hardly noticeable now. Cause remains unknown.
• Very easy and comfortable to drive. Continues to be eerily quiet in the cab on paved roads.
• At altitudes over > 9,000 feet the air compressor cannot reach a pressure over ~115 psi
• The Skymate system is much more valuable than anticipated for off-the-grid text communications
• Due to the peculiarities of the installation the genset air filter clogs quickly
• Very happy overall with the design, systems and capabilities

Service / Repair Log