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Aren't the blocks that are issued with these trucks the Skookum Model 62?

Not a bad idea. However, I think the air filter lid in particular is not flat, it's actually domed, which would make that one difficult.

The 3D printed stencil test went very well. I don't think anything on the truck is smaller than 0.5" tall letters. In this test, the 0.3" tall letters started to have some minor problems, where the diagonal cut across the zero is now cut completely out and the quote became one single hole...

Maybe/probably? My general philosophy is that anytime I have to do something that hasn't been done before, do it right and reproducibly so that other people won't have to do it for the first time [again]. That usually means it's more expensive for me to do it initially, but maybe it's worth a...

My overall guess is that there are smart people who are paid a lot of money to think about this stuff all day. If it worked better some other way (e.g. belts, chains, etc.) they would have done it by now so they could make a bunch of money off it. I bet there is a good reason they don't do it...

No, that plug is for something else, I think it's a CBRN alarm. The connections for the troop switch are in the wiring harness on the driver's side of the engine, near the oil dipstick.

I don't think an engine-driven hydraulic pump would work, because I don't think belts could handle the amount of power being put to it. Yes, there are PTOs that have remote shafts, so you can have the pump divorced from the PTO. However, it's the bolts on the actual PTO that are the worst. I...

It's not really a "better / worse" kind of thing. It really depends on a bunch of other factors, such as... How much do you care about it being original (either for historical reasons, or just that the ridiculously overbuilt nature of it will match the character of the truck)? How much...

A few days minimum. It's a lot of hassle. And then stuff doesn't work right... like I just had to have a new hose made, and for the life of me I can't get the tank clamps on (it's like they're too short, even though I know they just came off there).

After tons of searching, I came to the conclusion that no reasonably close font exists. So I hired a professional font designer to make me the exact font that I wanted, that matches each letter I could find in photos as closely as possible. Let me introduce "Tactical Vehicle" stencil font...

I love to tease my friends that if their "light duty" pickups can't handle it, I'll go get my "medium duty" truck. ;-)

Yeah, you're right. I don't know what I was thinking.

5 lights blinking is bad, but isn't 5 lights solid normal? That's how mine stays after it's aired up and good to go. Check the doc here in my signature for some info about the driveline issues, and other things you might like to know about.

Agreed, it's a hassle to install. Pretty much every bolt or hose can only barely be accessed from some other odd, contorted spot/position. Reach up over the muffler with a handful of univeral joints and extensions to get that one, raise the cab and reach down from above to get this one, buy a...

You would think that would be the case, but it doesn't seem like it. Years ago I started a folder on my computer called "Paint & Markings" where I put example pictures of stenciling on FMTVs. The pictures are collected from many sources (e.g. GovPlanet, user posts, military pictures, pictures...

What happens if you don't find out before you finish? I saw this video too, and was wondering if his operated normally. There was a thread here not long ago where the consensus was that it wasn't possible to have it in gear and run the winch.

You don't have the MTV manuals? Google for: TM-9-2320-366-10-1 - Operator's Instructions M1083 Series, 5 Ton, 6x6, Medium Tactical Vehicles (MTV) - Volume 1 of 2 - Sep1998

That's not very tough to make. Most CAD software (illustration software too probably, but I'm an engineer not an artist) can load in a background picture, and you just draw on top of it to approximate it.

The round circle with the arrow/harpoon through it? I can't really see what they are... picture is not high-res enough.

The N/W/V on your shelter look a little different than my collage pictures. Even so, these are getting really close. It may not be too much trouble to swap out a couple letters from a different font, perhaps. I found these other fonts were also fairly close...