ToDo – The Rig

Last Updated: 6/10/25

ENGINE

#	Done	Item	Details
1.		Block heater plug	Rewire to plug into house battery bank. Add timer switch with a toggle between block heater and hot water heater.
2.		Power steering pump	Tiny fluid leak
3.	✓	Brake master cylinder	Brake fluid leak between the master cylinder and reservoir. Need to replace rubber grommets.
4.	✓	Air compressor	Clean unloader valve – May be source of slow to build air pressure
5.		Air compressor	Input air tube is missing bolt on bracket, top of engine
6.		Hood	Replace left cable, Majority of open hood weight is on right cable which has broken fitting
7.		Hood	Devise hood lock mechanism
8.		Wiring harnesses	Various harnesses need wire loom and/or heat shield
9.	✓	EGR Valve	Clean EGR valve – Throwing error code: SPI 27, FMI 14 – EGR internal circuit failure – Fault sets when ECU determines EGR valve is not functioning properly when initialized – Possible causes: EGR valve unable to seat closed; stuck or sticking EGR valve – Troubleshooting: Remove, inspect and clean EGR valve; replace EGR valve
10.	✓	Coolant leak	Minor leak on front passenger side of engine
11.	✓	Oil in coolant	Suspect bad gaskets in oil cooler or under timing cover
12.		Oil analysis	Take oil sample and send for analysis
13.	✓	Radiator bracket	Both left and right lower bolts are missing a nut to secure the bracket to the frame via rubber bushings
14.		Hood insulation	Replace existing insulation

CAB

#	Done	Item	Details
1.	✓	Headliner	Clean & re-cover w/ trunk liner
2.	✓	Ceiling/floor/doors/walls	Add sound deadening and thermal insulation; Kilmat, mineral wool, adhesive foam panels sealed with Reflectix and aluminum tape
3.	✓	Center console	Remove storage
4.		Horton control panel	Move to lower center console. Connected to Intelliplex via a single cable with 4 conductors.
6.		Engine brake switches	Move to center dash panel
7.		Center dash	Replace panel; remount switches, air filter meter, cigar lighter, radio head unit, storage, air brake control
8.		Transmission control unit	Adjust height if possible
9.		Air filter minder	Not connected to anything in dash; Should be air line running through firewall to intake filter housing.
10.	✓	Headliner, wall panels, floor	Clean & re-cover w/ trunk liner
11.	✓	Dome lights (white)	Convert to LED
12.		Reading lights	Convert to LED
13.	✓	Grill lights	Remove red flashers and mounts from grill
14.	✓	Battery drawer	Add locking latches

CAB, DRIVER SIDE

#	Done	Item	Details
1.		Gauge cluster	Clean clear plastic panel
2.	✓	Traffic GPS	Remove unit and wiring harness in headliner
3.	✓	Vent window	polish exterior glass
4.	✓	Side window	polish exterior glass
5.		Windshield	polish exterior glass
6.	✓	Vent window	Add security film to interior/exterior
7.	✓	Side window	Add security film to interior/exterior
8.	✓	Door pull	Replace
9.		Cruise control	Diagnose/repair
11.	✓	Dome light (red)	Convert to LED
12.		Door panel foot light	Convert to LED
13.		Door handle	Weather seal with silicone
14.	✓	Battery switch	Remove rust & replace lock washer

CAB, PASSENGER SIDE

#	Done	Item	Details
1.	NA	Seat	~~Install swivel~~
2.	✓	Vent window	polish exterior glass
3.	✓	Side window	polish exterior glass
4.	✓	Vent window	Add security film to interior/exterior
5.	✓	Side window	Add security film to interior/exterior
6.	✓	Door pull	Replace
7.	–	Running board/step	Bolt missing above fuel fill
8.	✓	Dome light (red)	Convert to LED
9.		Door panel foot light	There is a power connection, but no light in the door panel, just an empty clear housing, convert to LED
10.	✓	Door handle	Weather seal with silicone

CAB, EXTENDED

#	Done	Item	Details
1.	✓	Jump seat	Remove
2.		Floor	Level out floor to remove lumps from cab bodywork
3.	✓	Vent window	polish exterior glass
4.	✓	Vent window	Add security film to interior/exterior
5.	✓	Flashlight charger	Remove charger base unit and wiring; wiring is 12V that runs under cab floor up to module electrical; preserve for fan or light
6.	✓	cab/module gasket	Repair or replace gasket between cab and module
7.	✓	Jump seat mounting holes	Seal with rubber stoppers
8.	✓	Sound insulation	Add Kilmat sound deadening to all accessible exterior body panels
9.	✓	Thermal insulation	Add mineral wool insulation to passenger side and driver side walls
10.	✓	Thermal insulation	Add adhesive foam insulation to indents of roof
11.	✓	Vapor barrier	Line floor, ceiling and walls with Reflectix sealed with aluminum tape
12.	✓	Rear bulkhead	Paint with rust reformer
13.		Rear pass-through	Modify to decrease width of opening and add pocket door.
14.	✓	Bulkhead wiring	Cleanup wiring behind cab locker
15.	✓	Driver rear corner	Seal seam in body at the bottom of rear bulkhead on driver’s side.
16.	✓	External locker mount	Paint with rust reformer where accessible

CAB, ROOF

#	Done	Item	Details
1.	✓	Traffic GPS	Remove antenna from dome
2.	✓	Light bar	Modify into trail light or remove light bar wiring harness and brackets
3.		Battery tender	Install solar battery tender for service batteries
4.	✓	Roof holes	Repair and seal 3 antenna holes

MODULE, ROOF

#	Done	Item	Details
1.	✓	A/C Unit	Remove
2.	✓	A/C Unit mount	Remove, clean adhesive, patch holes, clean paint, prime & paint damaged area
3.	✓	Antennas	Remove mounts and wiring
4.		Front antenna hole	Prep for cell booster antenna
5.	✓	Rear antenna hole	Seal
6.	✓	MaxxAir Fan	Install in A/C opening
7.	✓	Solar panels	Install solar panels and combiner box
8.		Awning	Install roof-mount awning on passenger side

LOCKER, CAB (Toolcrib)

#	Done	Item	Details
1.	✓	Shelves	Add shelving, drawers, tool holders
2.		Robinson shutter	Clean, oil, add secondary lock
3.	✓	120V outlets	Add 120V outlets for Milwaukee battery chargers (2)
4.	–	12V	~~Add 12V covered outlets (2)~~
5.	–	Interior	~~Polish aluminum~~

LOCKER A

#	Done	Item	Details
1.	✓	Oxygen tank mount & regulator	Disassemble and remove
2.	✓	Oxygen tank sensor harness	Remove
3.	✓	Door lock & catches	Clean & lubricate
4.	✓	Door insulation	Replace foam with mineral wool & seal with Reflectix
5.		Door handle	Weather seal with silicone
6.	✓	Diamond plate	Polish
7.	✓	Hinges	Polish inside and outside of door hinges as well as screws

LOCKER B, UTILITY

#	Done	Item	Details
1.	✓	AC wiring	Remove
2.	✓	Suction pump	remove
3.		Rollover sensor	Determine if it can be removed w/o pissing off computer
4.	✓	Airbag charge	Inert and remove
5.	✓	Electrical cabinet	Fabricate vented partition to divide locker between electrical and plumbing. Reinforce floor to support batteries. Install electrical mounting board
6.	✓	Door lock & catches	Clean & lubricate
7.	✓	Door insulation	Replace foam sound insulation with mineral wool & seal with Reflectix
8.		Smoke detector	Wireless smoke detectors in cabinet, cab and module
9.		Leak detector	Water leak detector to monitoring
10.		Vent	Reroute existing vent to cabinet
11.		Door handle	Weather seal with silicone
12.	✓	Diamond plate	Polish
13.	✓	Hinges	Polish inside and outside of door hinges as well as screws

LOCKER C, REAR DRIVER SIDE

#	Done	Item	Details
1.	✓	Door lock & catches	Clean & lubricate
2.	✓	Door insulation	Replace foam sound insulation with mineral wool & seal with Reflectix
3.		Door handle	Weather seal with silicone
4.	✓	Diamond plate	Polish
5.	✓	Shelves	Add five additional diamond plate shelves
6.	✓	Drawers	Install two drawers under existing shelf
7.	✓	Door mounts	Polish mounting blocks
8.	✓	Hinges	Polish inside and outside of door hinges as well as screws

LOCKER D, REAR PASSENGER SIDE

#	Done	Item	Details
1.	✓	Door lock & catches	Clean & lubricate
2.	✓	Door insulation	Replace foam sound insulation with mineral wool & seal with Reflectix
3.		Door handle	Weather seal with silicone
4.	✓	Diamond plate	Polish
5.	✓	Hinges	Polish inside and outside of door hinges as well as screws

LOCKER E, FRONT PASSENGER SIDE

#	Done	Item	Details
1.	✓	Door lock & catches	Clean & lubricate
2.	✓	Door insulation	Replace foam sound insulation with mineral wool & seal with Reflectix
3.	✓	Refrigerator install	Adjust shelving and drawer, mount fridge
4.	–	Vent	Venting for fridge
5.		Shelves	8020 shelves for exterior access
6.		Shower plumbing	Install shower head and faucets for exterior shower
7.		Electrical	Extend 120V electrical to shelves and replace outlet with GFCI
8.		Door handle	Weather seal with silicone
9.	✓	Diamond plate	Polish
10.	✓	Air compressor	Install
11.	✓	Hinges	Polish inside and outside of door hinges as well as screws

MODULE, INTERIOR

#	Done	Item	Details
1.	✓	Warning stickers	Remove
2.	✓	Squad bench seat belts	Remove
3.	✓	CPR bench seat belt	Remove
4.	✓	CPR bench airbag charge	Inert and remove
5.	✓	Attendant airbag charge	Inert and remove
6.	✓	Oxygen & suction systems	Remove
7.	✓	Attendant seat	Remove
8.		A/C heatpump unit	~~Remove~~ Evaluate modification/reuse
9.	✓	Stryker track	Seal holes, remove mounts, make flush with floor or use for table mount
10.	✓	Ceiling/walls	Add insulation where possible
11.		Squad bench	Convert to pull out bed/couch
12.	✓	Florescent lights	Remove fixtures
13.	✓	Halogen lights	Remove
14.	✓	Ceiling finish	Beadboard paneling
15.		Smoke detector	Wireless smoke detectors in module, utility cabinet and cab
16.	✓	CO/Gas detector	Carbon monoxide/propane detector
17.	✓	Kitchen	Install kitchen counter, replacing exiting countertop
18.	✓	Sink	Install sink, faucet and drinking water tap
19.	✓	Cooktop	Install 1 burner induction cooktop
20.	✓	Shelves	Modify storage for access to kitchen counter
21.		Kitchen counter	Add inset storage
22.	✓	Kitchen counter	Add under-counter drawer between sink & cooktop
23.	–	Kitchen counter	Add foldup counter
24.		Head	Install incineration toilet

MODULE, REAR EXTERIOR

#	Done	Item	Details
1.	✓	Stickers/emblems	Remove
2.	✓	Windows	Polish, add security & privacy film
3.	✓	Traffic controller bar	Polish lenses
4.	✓	Left-side door window	Reseal window frame
5.	✓	Door lock & catches	Clean & lubricate
6.	✓	Door insulation	Replace foam with mineral wool and seal with Reflectix
7.		Door handle	Weather seal with silicone
8.	–	Lights	Weather seal with silicone
9.	✓	Hinges	Polish inside and outside of door hinges as well as screws
10.	✓	Rear bumper	Repair and polishing bumper

MODULE, SIDE ENTRANCE

#	Done	Item	Details
1.	✓	Step light	Replace with LED strip lights
2.		Ground light	Add LED strip light for exterior ground illumination
3.	✓	Grab handle	Mount grab handle on left wall
4.	✓	Door grab handle	Mount large handle
5.		Diamond plate steps	Polish
6.	✓	Door lock & catches	Clean & lubricate
7.	✓	Door insulation	Replace foam with mineral wool and seal with Reflectix
8.	✓	Window	Add security & privacy film
9.		Door handle	Weather seal with silicone; repair broken latch handle
10.	✓	Diamond plate	Polish
11.	✓	Hinges	Polish inside and outside of door hinges as well as screws

UNDERBODY

#	Done	Item	Details
1.	✓	Bottom-rear edge of cab	Clean up rust, prime & paint
2.		A/C heat pump condenser	TBD
3.	✓	Bendix Air Dryer	REPLACED
4.	✓	WABCO HCU	REPLACED. Pumps run at start and periodically to pressurize brake lines
5.	✓	Batteries	Remove non-essential connections
6.	✓	Cab	Apply rust inhibitor/bed liner to exposed areas
7.		Greywater tank	Install greywater tank with remote drain valve

WHEELS, FRONT

#	Item	Details
1.	Wheels	Polish
2.	Lug nuts	Clean threads
3.	wheels/tires	replace with wider construction tire/wheels

WHEELS, REAR

#	Item	Details
1.	Outside wheels	Polish
2.	Dual wheels	Install pressure equalizer
3.	Lug nuts	Clean threads
4.	Wheels/tires	Replace with super singles

MISCELLANEOUS

#	Done	Item	Details
1.	✓	Cab/module body	Touch up white paint pen
2.		Cab/module red decals	Touch up w/ red paint pen
3.	✓	Exterior halogen lights	Convert to LED
4.	✓	Red emergency LED lights	Replace with blank panels
5.	✓	Center front vent	Replace center front light head on module with trailer vent
6.		~~Module exterior lights~~	~~Weather seal with silicone~~