Pappy, talk about how have you been improving the ergonomics in your rig that allowed such a sustained journey. How is your body?
I did five things to make this trip comfortable, or as comfortable as a leaf-sprung buckboard can be.
1) New suspension. I took off the old, stiff, AllPro 4" springs I had in front, and installed 2.5" OME. This did two things. It lowered the truck making it easier to get into, and it softened the ride. I kept the Alcan in the rear.
2) New seat. I pulled the Corbeau Moab seat I had, which was miserably uncomfortable, and installed a Mastercraft Baja RS. This seat was night and day the best improvement I made. I would not have been able to do a trip like this with the Corbeau seat.
3) Sound insulation. I put butyl/foil sound deadening in the truck. I did not get everything I wanted done. The only surfaces I did were the sides of the truck from the tailgate to the front doors. This did make a big difference, but I really need to insulate the floor too.
4) New exhaust. I pulled the Mangaflow muffler I had out and put in a slightly quieter Flowmaster.
5) New foam in the RT. OK, this was not something I did to the truck, but it did help me recover after a day on the trails. The foam that came with the tent was 2.5" thick. I replaced it with 3" medium density foam with a 1" memory foam mattress topper. There were only a few nights where I wasn't comfortable. Most of the time I didn't sleep well was because I was cold, not because of the foam.
I can honestly say that even though I was driving 6-10mph over baby-heads all day I did not feel beat up at the end of the day.
I actually made a list of things I did to get ready for this trip. It was divided into Comfort and (P)Maintenance/Repair. Other "comfort" things I did was the WeBoost cell booster, and replace the old stereo.