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Moved to generator forum.

I have been on 3 MVPA Convoys with Lamar. He is a great guy and always fun to be around.

I do not remember the zener diode number or value. But I suspect there are more issues with the card than the zener. You can test the GP's while still in the engine, remove the green wire from the tab and check the resistance from the tab to a good ground connection. Keeping the batteries on...

Sounds like your card has failed in a way that has latched the relay to ground. It would be best to get a new card and I would stop using a booster. My shop has seen several two way radios damaged from capacitive discharge type boosters. I would recommend using regular jumper cables from another...

Sounds like a dead battery or dead batteries. 23.2 volts before starting sounds low. Check the voltage on each battery when trying to start the truck. One or both are low.

Start the truck and then pull the card. Practice pulling the card out first with no power applied so you know how the get it out. As for export shipping. See if you can use someone that is experienced with shipping items out of the US. There are people that can provide that service. I know that...

Yes, CUCV Front Cover

I agree with Marcus. Get the truck back so you can work on it. Did you replace the GP relay with the proper one? It needs to be an isolated relay that has no common connection between the relay coil and the high current contacts. Proper replacements are a NAPA ST85 or a Trombetta...

I had to cut a hole in the floor board as Rick mentioned to get one out on my M1008.

Had a great time riding around the trails in the Gamma Goat. My newly designed camp set up worked well for me with the CUCV.

It's not my truck, so I am unable to answer your question.

Here is a nice rig.

Great work! Just because it may look good doesn't mean it is. Now is the time to check and correct every connection.

Looking good.

Noise suppressor, delete it if you want. Otherwise it may become an issue later.

Moved to proper forum.

Good detective work John. As you have found, the most important part of a high current electrical connection is the part that you don't normally see. That bad connection has been going on for awhile. Now is a good time for a preventative maintenance check up on all the battery and related...

I plan on arriving Friday morning. Bringing the CUCV Comms truck.

Welcome to the site. There are a few threads in the Trailer forum on converting a trailer to a camper type vehicle.

Put it together with screws. Test fit, then adjust as needed.