Outstanding build to be sure! I just spent the better part of 3 days reading the entire thread, from post 1 to current. During this time I took many side trips to investigate many of the links posted here about ideas, products and other rigs. This thread (And the build) are truly epic and completely deserving of being pinned in place so that years from now it remains at the top for those that wish to follow in your footsteps to be able to easily find. Thank you for not only posting about the build but taking the time to be as informative and descriptive as you have been. The information will be invaluable to those that follow. And just as useful will be the "Bloopers" that you mentioned you would tell us about. Listing and describing the mistakes made along the way is every bit as helpful as everything else you have posted. I for one and looking forward to that and a final recap/report when it is competed and again after 12 months or so of use. (And don't forget plenty of pictures of the rig And trailer) in use!!)
I understand your busy with "Real life" but it has been over a month since an update, sooooo, I just have to ask... "Any updates available?"
I think we are still waiting for more details/pictures of the final design of the back wall of the pop-up section, pictures of the completed interior and of the completed exterior. Also what have you decided about suspension modifications?
Unless I missed it your not installing air conditioning, is that correct? Those of us who live in the south east USA (Florida, Georgia, Alabama, Mississippi) pretty much consider A/C mandatory. I know where you live it usually does not get as hot or humid as it does for us. I really like your idea of barely using the generator, mostly relying on the solar to keep your house batteries charged. I'm not sure that we could do that here in the south east. The energy draw of even a single A/C unit would probably require so much battery bank (To run all night) that it would be impracticable, and so many square inches of solar panels it would not be possible because you would need more sq/in than the total of your roof. I do remember seeing a link in a thread recently, (Might have been this one) where somebody was asking about a unit intended for RV use that is roof mounted and looks similar to a "Normal" RV A/C unit but is actually an evaporation or "Swamp cooler". They use far less electricity than a compressor driven "Normal" A/C system but with the high humidity in our region, they are all but useless for decreasing the air temperature so where we really need it, they are not a viable option.
The only real question/suggestion I have had during the process is why did you not put a rear mounted self recovery winch? It looks like you have plenty of room to install one just above the receiver hitch unless the spare tire does not allow for the depth needed. In which case I would be very tempted to mount one "externally" on that plate in the same place and trim/dress/reinforce as needed to install a roller fairlead and make it look good.
I bring this up because many people do not understand the value of a rear mounted self recovery winch. Personally, if I could have only 1 winch it would be on the rear rather than the front. The argument for this? Consider this; Your driving along the trail for the day and become stuck. With only a front winch your choice is basically limited to winching further into the mess that currently has you stuck. Depending on the situation this may not be totally bad, but on the other hand.... Now consider that 5 feet ago you were not stuck. If you could simply winch backwards 5 or 10 feet your rig would be in a location that you were driving and did not need a winch. From that point you could choose to pick a new line to try to proceed, go around, or abandon the current plan and find a completely different way rather than winch further into the mess that currently has you stuck. Just a thought..
Oh, and now that it is way to late, my vote for color is; Tan, Desert sand or whatever you want to call it. Even leaving the cab white with everything else tan would be acceptable if needed for financial reasons.
The color issue reminded me, I wanted to ask; The Scorpion material you used for the exterior, how is it different from, or similar to, "Pick up truck bed liner"?
In closing, You may have posted it already and I missed it, but your job obviously both pays relatively well and allows you enough time off to justify the time and expense of building a rig like this, (And one would assume the time to use it once done) so I am curious. What line of work are you in?