Category Archives: Tea

2015/11/16 (M) Tiling the Cockpit, #3

Linda planned to go to the bakery today but decided yesterday to stay home and help me instead.  Based on the 10-day forecast this looks like our last decent weather day to work on the bus and we wanted/needed to make the most of it.

We had breakfast at 8 AM (granola with blueberries and a banana) and had a cup of Stash China Black tea.  I had a text message from Kristine Gullen regarding getting together with her and Jim on Saturday and replied in the affirmative.  We finished our tea by 8:30 and got to work.

I really wanted to finish tiling the cockpit of the bus, or at least as much of it as we could.  That meant cutting and fitting tiles for the stair treads and risers and the two side walls of the entry steps, gluing them in place, and then grouting all of them.  We needed to mount the table if possible and I also needed to build a new step for the platform.  That was a lot to get done in one day and even before we started I doubted that we would get it all done.

When we opened the bus we were surprised to find that the tiles on the walls of the platform had slipped all the way down to the floor tiles.  Obviously I should not have removed the spacers right after installing the tiles and should have to left them in place for any horizontal grout spaces on vertical surfaces.  Oh well, not much to do about it now.

Keith called to see if he should come and mulch the leaves one last time.  The weather the last few days had been very nice, unseasonably warm and dry.  Today was also a beautiful day but the forecast going forward was for much cooler and wetter conditions, so this was an ideal day for our last lawn mowing of the 2015 season.

We measured and cut the tiles for the face of the platform and out to the door.  At that point I evaluated what I needed to do to complete the job.  Basically, I needed to cut all of the tiles for the entry steps and walls and then install them from the bottom up.  Every piece of tile was going to be smaller than a full 16″x 16″ tile and custom cut so even though the square footage was not that much there would be more pieces than usual and it was obviously going to take quite a bit of time to get all of the pieces ready to install.  I thought we could be ready for adhesive in two hours but Linda figured it would be at least three.  It also meant working with the door open which would make it difficult to keep the interior as warm as we needed.

Phil showed up with his excavator and a dozen bales of straw.  I knew the excavator was for a different job as he did not have anything left to do at our place that required it.  He was here to finish covering the topsoil and grass seed with the straw.  We took a break to go talk to him and confirmed that he was done with the driveway and French drain projects except for the straw.  He staged the bales where he needed them but said he had to leave to dig a perk test hole at 1:30 PM and would be back mid-afternoon to finish spreading the straw around.

Linda suggested that we go ahead a grout all of the tile we had already installed.  I was more emotionally invested in completing the tile work than Linda but had to agree that this was the prudent thing to do.  Until the tile was grouted we could not reinstall the accelerator, the steering column shroud, the seat bases, and the seats, so grouting the tile was clearly a critical path item and that is what we did.  It was after noon by the time we finished so we took a break for lunch.  Phil had taken off by this time to go dig the test pit.

Lunch was grilled vegan Italian sausage on a bun with mustard and relish and black grapes on the side.  Keith finished up mowing the yard while we were enjoying a cup of Rooibos tea.  We paid him and chatted about next year.  I gave him our approximate timeframe for returning home from Florida and asked him to go ahead and start mowing next spring whether or not we were here.  We have had Keith take care of our lawn since we bought our house in the country and he has been very good about doing that when we are away and allowing us to catch up with him when we get back.

By the time we got back to work on the bus it was after 1 PM and I had to concede that we were done working on the tile until next spring except for cleaning them, which had to wait until tomorrow as the grout has to cure for 24 hours before final cleaning.  With that decision made we considered what else needed to be done and in what order.

The first order of business was painting the two front seat bases black.  We spread out painter’s plastic on the driveway and taped it down.  We set the bases there and then masked off the top portion with the swivel bearings and mounting bolt.  We wire brushed the bases to remove rust and then went over them with a sanding sponge.  I used a cleaner/degreaser and water to clean them and then gave them a coat of black rubberized undercoating paint.

The next order of business was getting all of the tools and materials that we no longer needed out of the bus to give us room to work on other things.  On Saturday I re-installed the bump out on the walnut cover for the passenger side HVAC duct.  The duct needed to have two 4″ holes drilled in it to match the holes in the metal duct, so that was the next task.  I measured very carefully and transferred the measurements to the face of the cover with equal care.  Even so, I was off slightly and had to use the sheet metal nibbler to enlarge the bottom of each hole.  At least I had a relatively straightforward way to fix this problem; I am not always so lucky.

With the holes enlarged we put the cover in place.  The 4″ round plastic registers fit through the wood into the duct but not all the way due to two tabs.  I trimmed the tabs off using the Porter-Cable oscillating saw and trimmed a little bit off of one of the outer mounting flanges to make it fit flush.  I drilled holes through the two mounting holes on each register using the #5-6 self-centering drill bit and secured them with #6-5/8″ SR screws.  We then removed the two temporary black plastic registers from the front of the built in sofa.  I trimmed the tabs off of two new brown ones and installed them using the same procedure as the first two.

In the grand scheme of things getting the cover in place and the four registers installed was a small task but it needed to be done and stood in the way of other things.  The cover has been stored on top of the two front seats, which have been lying on their backs on the kitchen floor of the bus for weeks.  We plan to re-install the seats late tomorrow afternoon.

Two more small, but critical, tasks were securing the pull-out pantry and the refrigerator.  I have assumed for quite a while that we would secure the pantry for travel with some form of sliding latch but had not thought about it in any detail.  We also needed to secure the refrigerator but I had not thought about this in any detail either.  As we pondered the pantry latch it slowly became obvious that we did not have enough wood for a strike plate to receive a pin and we did not have two unobstructed surfaces that were in the same plane, which would be required for the kind of latch I had been thinking about.

As for the refrigerator, one of our bus nut friends secured their unit by running mounting bolts (machine screws) through the floor of the cabinet above the fridge and threading them into the unused tapped holes provided for the upper door hinge (if it was reversed) .  After looking at it for a while we realized that we could attach a section of small angle to the inside of the right alcove wall with the other side just against the face of the fridge case but not over so far as to interfere with the door gasket.  My measurements indicated that a 1/2″x3/4″ angle would be just right.  It looked to me like two 12″ pieces, one by the freezer door and one by the bottom of the fresh food compartment door, would be more than adequate to keep the refrigerator from rolling out as it cannot shift sideways or twist due to the aluminum angle on the left/hinge side at the floor.

About this time Phil returned in a red pickup truck.  He finished distributing the straw and loaded three unused bales into the back of his truck.  He pulled up in the main drive and we invited him into the bus to see what we had been working on all summer.    It is always a pleasure working with Phil.  If/when we build a barn we will have him do all of the site prep and finish grading.  He will figure out the final cost for the driveway extension and French drain and send us an invoice.

Linda prepared an easy but tasty dinner consisting of a nice green salad, mixed frozen vegetables (corn, peas, and carrots) suitably reheated, and mac-n-cheese that was both dairy-free and gluten-free.  After dinner we went to Lowe’s and The Home Depot.  At Lowe’s we bought a 1/16″ thick 1/2″x 3/4″ aluminum angle and three 8 foot lengths of brass colored nose edging but did not find a latch that we liked.  At The Home Depot we bought some screws for securing the handle on the front of the pull-out pantry and a solid brass door stop to keep the pantry in place.  The door stop folds up when not in use and should work to keep the pantry closed while traveling.

Although the new Panera on the southwest corner of Grand River Avenue and Latson Road was finally open for business we stopped at Teeko’s Coffee and Tea on the northeast corner of that intersection.  Jeff was there and took our order for eight pounds of coffee beans.  We got two pounds each of Ethiopian Yirgacheffe, regular and decaffeinated, the Seattle Blend (regular), and the Sweet Dreams blend (decaffeinated).  They will roast the beans and then let them outgas for a few days before vacuum sealing them in half-pound portions.  This allows us to take them with us in the bus and keep them very fresh until we are ready to use them and to change what we are drinking more often.

We got home just after 8 PM and took our iPads downstairs to use while we watched our Monday evening CBS TV programs.  We caught the weather forecast and then headed to bed.  It looks like we will have two more days with unseasonably high temperatures near 60 degrees F but with intermittent rain and then a serious cooling trend with highs this weekend barely above freezing.  Our time for working on the bus and being in Michigan is definitely running out.

 

2015/11/12 (R) Unforced Solutions

When I got up at 7 AM Linda had already left for the bakery.  I had granola for breakfast and made a cup of Stash China Black hot tea.  I went to my office and processed the photo that Byron sent me of him and Betty and e-mailed it to Gary and Jorge at Bus Conversion Magazine.  I then replied to an e-mail from Nancy (& Big Bill).  We met them at Suncoast Designers in Hudson, Florida in April 2014.  They are from Ontario but have a place near Ocala, Florida where they spend at least part of the winter.  I also replied to an e-mail from the Mitch in Florida regarding good places for bus service and forwarded my reply to Chuck.  I cleaned the kitty litter tray and finally got to work on the bus.

A piece of scrap SurePly underlayment used as a spacer/guide for the Porter-Cable oscillating saw to undercut he bottom edge of the side wall panel so it can be removed above the floor tile.

A piece of scrap SurePly underlayment used as a spacer/guide for the Porter-Cable oscillating saw to undercut he bottom edge of the side wall panel so it can be removed above the floor tile.

First up was to finish screwing the down the SurePly underlayment on the floor of the passenger seat platform.  With that done I turned my attention to trimming the switch panel next to the passenger seat.  This panel is just 1/4″ walnut veneered plywood but has both AC and DC switches mounted in a row across the entire top portion.  The added thickness of the underlayment and tile on the floor and back wall of the platform required the bottom and back edges of the panel to be trimmed so it could be installed and removed in case I need to get to the wiring behind it.  I used pieces of underlayment as spacers/guides and trimmed off the edges using the Porter-Cable oscillating saw.  This was the perfect tool for this situation where I could not remove the panel and take it to the shop.

With the panel trimmed and the sawdust vacuumed up I turned my attention to the tile.  After test fitting some pieces to see where the edges would land I decided to tidy up the front of the bus so it would be easier to work.  While that was certainly true it was also a tactic of stepping away from the work and letting solutions float into consciousness rather than trying to force them out.  After several trips to bring things inside the house and garage it was noon and time for lunch, which meant more time to relax and let my subconscious work on the tile layout.  Hummus and sourdough pretzel nibblers made a quick, easy, tasty meal and a cup of Constant Comment decaffeinated tea helped wash it down and warm me up while I worked on this post.

Two scrap pieces of the Armstrong Alterna Luxury Vinyl tile used as feeler gauges to make sure the side wall switch panel will clear the floor and rear wall tiles.

Two scrap pieces of the Armstrong Alterna Luxury Vinyl tile used as feeler gauges to make sure the side wall switch panel will clear the floor and rear wall tiles.

As long as I was taking a break I called Pat/Vickie Lintner to let them know I would be coming through Elkhart tomorrow (Friday) and verify that they would be home in the morning.  That sounded fine to Pat.  I will be picking up an accessory for a Nutone power base unit from them.  We have one of the power bases installed in the kitchen counter of the bus but the blender was the only accessory that came with the bus when we bought it.  Pat and Vickie had a power base in their bus but it broke years ago.  They never replaced it, and don’t plan to, so they no longer needed the accessories and were willing to give them to us.  We got most of the pieces from them at the GLCC Surplus and Salvage Rally back in September but we were missing a critical piece which Vickie thought she still had and eventually found.

After my break I reinstalled the large front trim board on the driver side vertical wiring/plumbing chase that is located on the outside wall next to the back of the driver’s chair.  I don’t recall how I got it out but I could not get it back in.  I ended up trimming off a small protrusion on the lower end and then it went into position without any further difficulty.  It was a small thing, but it needed to be done and it was good to get it checked off my (mental) “to do” list.  When I cannot solve the problem I am trying to solve (tile layout) I try to keep moving and get other small tasks completed.

I took a few more minutes to carefully measure the adjustment needed to the bump out on the passenger side HVAC duct cover and the dimensions for the two new pieces of walnut that will go on either side of the sofa seat.  I brought the old pieces in the house and found the leftover walnut in the garage as I have to take some of it with me tomorrow to Jarel’s cabinet shop in Logansport, Indiana.  I think an hour of my day disappeared between these small, simple tasks.

I continued to ponder the tile layout for quite some time, taking and retaking measurements as I tried to figure out an arrangement that would allow the joints to fall in reasonable places while making sure I could notch around things that go through the floor and avoid having any small pieces.  That is a lot of constraints.  The arrangement I finally came up with had three full 16×16 tiles centered on the landing and into the driver area.  There will be pieces about six inches wide along the fore and aft edges, and the first full tile will also be about six inches back from the edge of the landing (by the entry stairs).  The joints (grout lines) resulting from this placement will continue up the front of the passenger seat platform and result in tile placements on the platform that should work out well.

Linda called at 4:15 PM to let me know she was on her way home from the bakery and was stopping at Kathi’s on the way.  I was done working in the bus for the day so I adjusted the thermostats on the heaters and checked the house battery bank status.  The battery bank voltage was at 25.0 VDC, just slightly down from the 25.2 V level of a fully charged and rested “24 V” lead acid battery (2.1 V per cell x 12 cells in series).  The State Of Charge (SOC) was at 84% and I decided to leave the charger off until Saturday morning after breakfast.  I did have the shorepower turned off for a few hours Wednesday so the refrigerator was running on the inverter for a while but there are no DC loads operating in the coach at the moment and the Magnum remote is showing zero current coming out of the battery bank.  There must be some loads, however, as the battery SOC wound not drop that much that quickly due to self-discharge.  I locked up the bus, went in the house for the evening, and turned on the outside lights for Linda.  Given when she left the office I knew it would be dark by the time she got home.

I took a few pictures throughout the day so I went to my office and off-loaded them onto my computer.  I had an e-mail from Gary at BCM with the latest markup of the PDF for the December 2015 issue.  I proofread my article and highlighted a half dozen things that needed to be changed, using the sticky note feature for the first time to indicate the corrections, and e-mailed it back to Gary and Jorge.

Linda got home about the time I clicked ‘send’ so I wrapped up my desk work and went upstairs.  She had not been grocery shopping this week and wasn’t sure what to fix for dinner so I suggested vegan pancakes.  Fifteen minutes later we were enjoying flapjacks with real maple syrup and cups of hot tea.  Breakfast for dinner is always a treat.  We spent a little time in the living room by the fireplace and then went to the rec room to watch a few TV programs while we doodled on our iPads.  We have been trying to break the habit of watching TV in bed but we finished watching the last show in bed and then turned out the lights.  In a reversal of our recent usual morning routine I have to be up early and Linda does not, but she still fell asleep before I did.

 

2015/11/08 (N) SLAARC Elections

Madeline was in bed last night at 8 PM and fell asleep quickly.  We were in bed before 10 PM.  Linda fell asleep right away and I put my iPad away and turned off the light at 10:30 PM.  Good thing, too, as Madeline started coughing at 5:30 AM.  Linda got up at 6 AM and brought her into our bed.  I don’t know if she ever fell back asleep but we all stayed there quietly enjoying the warmth of the covers until 7:30 AM, by which time the house was warming up.  Hurrah for programmable thermostats!

Being Sunday morning, and having Madeline here, we were in no hurry to get up, get dressed, or get busy.  Not that we had nothing to do, we just were not in a hurry to do anything.  Linda prepared baked French toast last night, with a little help from Madeline, and let it sit overnight in the refrigerator.  She got up at 6:45 to pre-heat the oven and again at 7 to put the dish in to bake.

I got up at 7:30 and made coffee.  The downlight over the end of the counter where I make the coffee burned out last night so I replaced the bulb.  Linda set the table and took the French toast out of the oven at 8.  When she cut into it and served out pieces for each of us it was obvious that something was very wrong.  Instead of baked French toast we had inedible goo.  Linda has had very few recipe failures since we switched to a whole-food plant-based (WFPB) vegan diet but this one took first place.  She mentioned that it was a different recipe than she has used in the past and that she used an egg replacer she has not used before which did not seem to dissolve correctly last night.

Linda was willing to make vegan pancakes but I did not see any reason for her to go to that trouble.  We still had plenty of granola, part of a loaf of cinnamon raisin bread, and fresh berries, all of which made for an easy but tasty breakfast.]

Madeline plays (at) the organ.  It is one of her favorite “toys” at our house.

Madeline plays (at) the organ. It is one of her favorite “toys” at our house.

After breakfast I cleared the table and then read a book to Madeline while Linda cleaned off the dishes.  I turned on the fireplace and we drank our coffee in the living room while Madeline found various things to play with, ultimately ending up at the organ.

By 9:30 AM we were feeling like getting dressed.  I put in my work clothes and finally got to work in the bus at 10 after turning up the thermostats in the library, garage, and bus.  The first thing I needed to do was screw down the last/top layer of SurePly underlayment in the landing and driver area.  I used #6 SR (square recessed) self-drilling wood screws in three different lengths based on what was underneath the underlayment.  I chose to use screws rather than staples for several reasons.  The main one was that I needed the ability of the screws to pull things together.  The other reason was that I did not want to get the air compressor and stapler out for this relatively small number of fasteners.  (The SurePly underlayment for the main floor of the bus was stapled with approximately 350 staples per full 4’x8’ sheet.)

I pulled up the larger piece of SurePly one last time, measured the location of the boundary between the original bus floor and the new patch, marked the boundary on the top of the large piece, and put it back in place.  I carefully aligned the smaller piece to the stair edge and along the front and made sure the larger piece also fit correctly.  The smaller piece sits entirely on the new landing, which is 3/4″ plywood, so I secured it with 1″ screws, spacing them 2-to-3 inches apart along every edge and about 4 inches apart in the field.

The 1/2″ piece of plywood just forward of the driver’s seat was partially unscrewed and needed to be screwed back down.  Since it was installed over the original 1″ thick plywood bus floor I replaced the existing screws with 1-1/4″ screws and added more, especially along the edges.

To secure the larger piece I used 1-1/2″ screws over the patch, which was already about 1-1/4″ thick.  Over the original 1″ thick plywood bus floor I used the 1-1/4″ screws and over the 3/4″ thick landing I used 1″ screws.  I ran out of the 1″ length before I got the larger piece secured.  As much as I did not want to spend time driving around today I could not finish this task without the proper screws so around 11:15 AM I headed off to Lowe’s.  As long as I had to make the trip I looked for washers to space up the mounting bolts for the passenger seat pedestal base and nylon washers to go under the nut on the main mounting stud for the two swivel bases.  I found something that might work for the former but not the latter.

Linda and Madeline were getting ready to leave as I returned home just before noon.  Madeline was upset because Linda made her wear a sweater under her coat and she did not want to.  She is generally a cheerful and pleasant little girl but we never know when or why she is going to draw a line in the sand.  She doesn’t always or even usually get her way but she is persistent.  The tears, of course, are not the result of genuine injury and are usually quickly enough wiped away by focusing her attention on something else.  They finally pulled out of the driveway at 12:15 PM for an outing at Kensington Metropark.

I finished securing the larger piece of SurePly over the landing and then started on the next task.  I had decided to patch in an area at the end of the passenger platform where it drops down into the back of the driver area.  The area to be patched was only 12-3/4″ long and less than 4″ wide but the underlying metal was rounded over in this area and there wasn’t much I could use to attach new wood.  The area was also deep and not level.  I ended up making a sandwich with two layers of SurePly, two wood shins on top of those, and a piece of 3/4″ plywood on top.  I got all of the pieces cut and fitted and then marked them with pencil lines down the exposed edges to act as alignment marks.

I carefully assembled the sandwich upside down in the shop and screwed it together from the bottom.  I then put it in place in the bus and measured for a vertical piece with an angled rear edge to catch the outside edge of the patch and hold it up.  I secured the patch with one 1-1/2″ screw near the front and secured the vertical piece with one screw into the same piece of wood.

Building and installing this patch took a while and I was just finishing it when Linda and Madeline got home around 3:30 PM from their trip to Kensington Metropark.  By this time it was too late to start working on the underlayment for the passenger seat platform as I needed to stop working at 4 PM and get cleaned up for our amateur radio club meeting this evening.  With the little time remaining I unscrewed the top of the step and removed the two screws that held it to the rear and side walls of the co-pilot/navigator platform.  I then removed a half dozen flat head wood screws that held a piece of metal trim to the front edge of the platform.

The screws were rusted but came out.  The issue for my work was that the heads were not countersunk and stuck above the metal in a way that would interfere with installing the sheet of underlayment.  I used a 7/16″ drill bit to create tapered holes and may go back tomorrow and use my countersink bit.  I looked, but did have any appropriate screws to replace the ones I took out.  That meant another trip to Lowe’s which I could do after dinner on my way to the ham radio club meeting.

I put the two swivel pedestal/bases back in the landing and locked the bus.  I made sure everything was in the garage that needed to be and closed the overhead door.  I showered and shaved and put on clean clothes.  I then sat on the living room sofa with Madeline while Linda fixed dinner.  I worked on this post while Ms. M played games on Linda’s iPad.  It’s amazing to watch a 3-year old manipulate an iPad.  Their use of the touch screen is intuitive, which is cool, and it holds their attention in a way that other activities do not, almost to the point of obsession or addiction, which can border on troubling.  In spite of how much Madeline likes to eat, Grandma Linda had to gently take the iPad away and get her to come to the table for dinner.

As part of her food planning for this weekend Linda had picked up some mock turkey patties with gravy.  She also picked up some vegan heat-n-serve mac-n-cheese.  Those were the main course this evening along with a nice green salad and the rest of the fresh pineapple.  Dessert was going to be cake but I had to leave before it was served.

I left at 5:30 PM and drove to Lowe’s in New Hudson.  I monitored a QSO between Mike (W8XH) and Steve (N8AR) until Steve reached the meeting location in South Lyon.  I then called for Mike and we chatted until I reached Lowe’s.  I bought a box of 1-1/4′ long # 12 flathead wood screws and picked up three 40 W appliance light bulbs for the microwave in the house as the installed ones had burned out.

I got to the Witch’s Hat Depot at 6:35 PM so I had a chance to visit with my fellow hams before the meeting started at 7 PM.  Steve (N8AR) had a display set up with several different DC power meters he ordered off of EBay.  The business meeting was longer than usual because we had to elect officers for 2016.  The process was very smooth, surprisingly so actually, but still took 10 minutes.  The meeting was done by 7:20 after which the club president, Harvey (AC8NO), did a presentation on his Icom IC-7200 portable base station transceiver.

I was back home by 8:40 PM.  Madeline had already gone to bed so Linda and I had some quiet adult time to enjoy a cup of hibiscus tea.  We were both tired after long days of work and play but we did a lot today and felt good about the things we accomplished.

 

2015/11/05 (R) POR-15

Linda was back at the bakery today, so she was up early and gone before I even thought about getting out of bed.  Having her homemade granola as our standard breakfast means I can feed myself under such circumstances with very little time spent on preparation and cleanup.  I made a cup of Stash China Black tea instead of coffee; it’s quicker and cleaner.  I like tea, and only started drinking coffee at age 50, but this morning the choice was motivated by ease and quickness of preparation and minimal cleanup as I was anxious to get busy working on the bus.

My focus today was getting the areas in the cockpit where I cut out the old water-damaged plywood ready for the installation of new wood.  That meant getting POR-15 applied to the areas of rusted metal in the cockpit and spray painting over it with black rubberized undercoating paint.  I also wanted to start cutting and fitting the wood pieces that I will use to patch the floor.  I finished building a pair of sawhorses and set them up in the driveway just outside the large garage door so I could measure, mark, and cut wood at waist height.  I was working on one of the pieces when the whole house generator came on at noon, ran its exercise cycle, and shut down 20 minutes later.  Shortly thereafter I heard the rumble of a big truck coming down the road and a few seconds after that Phil’s truck and trailer drove past.

Phil drove to the west end of the property, turned around, and parked down there.  He brought his Takeuchi front loader and used it to spread the large pile of topsoil around the part of our yard where the French drain starts.  He filled in low spots and graded everything off to blend in nicely.  He then worked his way up the drain line towards the culvert that goes under the road.  When Phil was done moving dirt around he spread grass seed and loosely distributed three bales of straw.  That gave him a good idea of how much more straw he would need.

I eventually took a break and walked down to chat with him in the middle of all that work.  He finished moving some dirt and also took a break for lunch.  He will have a load of screened topsoil delivered as soon as he can to use on both sides of the new gravel driveway.  He also clarified that the 40 foot parking pad portion of the driveway is probably not flat/level as it is not finished yet.  When he places and grades the topsoil his equipment will tear up the driveway a bit.  He will then use his bulldozer to finish the driveway, making sure the pad is flat and level.  That was a relief as I thought he was done and I was fairly certain the pad was not flat or level.

By 2:30 PM I finally had the areas of rusted metal prepared and masked off with painter’s plastic.  I applied the POR-15 with a foam brush.  In spite of being careful I got some on my hands and in retrospect should have worn disposable gloves.  The only way to get this product off of things, including skin, is with the POR-15 solvent, which I had failed to purchase.  Once dry it is permanent, so my right hand is going to look like I just changed the oil on the bus until the old skin gets replaced with new.  The drying time for the POR-15 is 2 to 6 hours.  The afternoon high temperature was 72 degrees F so I figured I would check at 4:30 PM.  The directions said I could paint it while it was still tacky as long as it set enough not to transfer.

Linda got home around 3:30 PM and changed into her work clothes.  Phil was still here working but we left him alone.  The weather forecast for overnight and into tomorrow was for rain, possibly heavy, so we did not want to cause any delay in Phil’s work.  I had cut and fit four pieces of wood earlier.  We put painter’s plastic over the sawhorses and laid them out bottom sides up.  Linda put 2×4 blocks under them to get the edges off of the plastic and I coated them with Thompson’s Water Seal.  I am doing what I can to protect this new wood from water damage.

I needed to finish masking off the cockpit with painter’s plastic before spraying the black rubberized undercoating paint so Linda helped me with that.  The plastic is very thin and much easier to handle with two people.  While we were doing that Phil drove past.  We took a break and walked down to west end of the property to see what Phil had accomplished today.  Back in the bus we had the area masked off to my satisfaction by 4:45 PM.

The base of my thumbs were bothering me (arthritis) so Linda shook the paint can for the required three minutes.  Although the light was fading due to the hour of the day and the cloud cover, I was still able to see well enough to spray the paint where needed.  That was the end of our work for the day, except for cleaning up, and I was satisfied with what we had accomplished.  We put some painter’s tape over three areas where we thought water might be getting in and then started putting everything away.

The wood pieces we treated with Thompson’s Water Seal were still wet so I picked them up from underneath and carried them into the back of the garage.  Linda brought the blocks in and set them on the floor and I put the pieces back on top of the blocks.  The directions said to allow at least 48 hours for drying but I plan to flip them over and coat the other side tomorrow if possible.  We are running out of time and I cannot wait two days to seal the other side and then another two days for it to dry.  We put the various tools away, removed the plastic from the sawhorses, and moved the 2×4 stringers and the sawhorses into the small garage bay.  It was 5:45 PM when we closed up the garage and it was getting dark, a clear reminder that summer was behind us and winter was approaching.

We relaxed for a while before dinner.  Linda made a nice salad and reheated the whole wheat linguini she made the other night.  We opened the bottle of Frey Natural White wine to try it.  I liked it even less than their Natural Red, if that’s possible.  It was very dry and since I do not care for dry wines I was not able to judge its other qualities.  Linda did not care for it either, and she tends to be OK with dry wines, so I suspect it is just not a very good wine.  I suggested she find a recipe that calls for white wine and use the rest of it in the dish.

One of our favorite TV shows is The Big Bang Theory.  It has moved to Thursday evenings this season, so we went downstairs to watch it.  The problem is that once we are in front of the TV set we tend to stay there.  I use the time to multi-task and work on my blog post for the day, so it’s not a complete waste of time.  Besides, we do not consider being entertained a waste of our time.  I am enjoying working on the bus, and although some aspects of the work appear humorous in retrospect, I am rarely laughing while in the middle of it.  I like things that make me laugh, and The Big Bang Theory is a very cleverly written show that is well acted and very funny.

 

2015/10/29 (R) A Setback

Linda turned off her alarm and slept a few extra minutes before getting up at 6 AM.  I watched the weather on TV while she got ready to go to the bakery.  She left at 6:25, about 10 minutes later than usual.  I am always amazed at how quickly she can get showered, dressed, and out the door.

The temperature across our area was 37 degrees F, more or less, and the wind was blowing, which we could see just by looking at our trees.  The winds were forecast at 15 – 25 MPH out of the SW gusting to 40 and strengthening into the morning hours as they shifted out of the west in advance of a second cold front.

Last night I shut off the color laser printer, the two NAS units, and the Linux box as a precaution against losing power but left my laptop on since it runs on its own internal battery.  Even though all of our devices with hard disk drives are plugged into uninterruptible power supplies, and we have an auto-start whole house generator with an automatic transfer switch, I decided to leave all of these computing devices turned off until the wind subsided later today.  Morning showers were forecast as likely, with the possibility of a few snowflakes, but never materialized.  Overnight lows tonight are forecast in the mid-to-lower 30’s.  The bus is not winterized, and I have been working in it almost every day, so I have had the heat turned on in the bus for most of October.  I do, however, set the thermostats back to approximately 55 degrees F when I am done working for the day.

I got up, put on my robe, fed the cats, and made a half pot of coffee (Sweet Seattle Dreams).  While the coffee was brewing I heated up a banana-nut muffin, poured a small glass of orange-grapefruit juice, washed the last of the blueberries, and fixed a bowl of granola.  I was done with breakfast by 7:15, took my coffee to the living room, and enjoyed it by the warm glow of the fireplace as I worked on my iPad with Juniper on my lap and watched the night yield to the orange glow of sunrise.

New photo accessories from B&H Photo Video in New York, NY.

New photo accessories from B&H Photo Video in New York, NY., photographed with the new Sony a99v-DSLT camera.

My main focus today was the cockpit of the bus, specifically the floor/wall tile, but first I got dressed, turned up the heat in the bus and the garage, and then opened the boxes that arrived yesterday from B&H Photo.  I managed to do that at 8:30 AM; well ahead of my usual getting started time of 10 to 10:30 AM.  Most of the items were in one large box but two small items were in a separate box that must have been shipped from a different location.  The shipping boxes were in good shape and the B&H sealing tape was intact.  I removed everything from the shipping boxes and then checked them off on the packing slip.  Again, all of the individual product boxes and other packaging were undamaged.  I opened each item, carefully removing all of the pieces and manuals/paperwork.  I arranged everything on the dining room table and took a few photos to document what was there.

I had been pondering the damaged plywood under the driver’s seat ever since I removed the old vinyl tile.  The exposed plywood was screwed down in lots of places so I figured it was not the original floor of the bus.  I could also see many additional plywood layers in the holes for the seat mounting bolts.  Closer inspection revealed that the top layer of plywood in the driver’s area was in two pieces, fore and aft, and that only the aft piece was damaged.  Based on all of that information I decided to try removing the aft piece.

All of the screws came out except for two and they just spun in their holes so I figured the wood around them was bad.  It took a little prying but the piece popped loose.  I pushed the two power wires for the motorized seat back through a hole and the board was free.  What I found made my heart sink.

First look at the water damage in the aft portion of the driver’s floor area.

First look at the water damage in the aft portion of the driver’s floor area.

The underside of the plywood was much more damaged than the top side and it was moist.  The original bus floor was even worse.  Part of it was missing and I was able to crumble much of what was still there from the rear mounting holes back.  It was obvious that there had been considerable long-term exposure to water but it was not obvious how this had occurred and was, apparently, still occurring.  I texted Linda and Chuck with a photo of the damage and heard back from both of them fairly quickly.  This was clearly an unanticipated setback but long term it was better that I discovered it, and had a chance to fix it, rather than having covered it up.

Speaking of covering things up, the top layer of plywood must have already been damaged when we bought the coach in late 2009.  One of the things we had Creative Mobile Interiors (CMI) do to the coach between September 2009 and April 2010 was pull the carpet out of the entry and cockpit and replace it with the gray vinyl tile that I just removed.  The tile was under the swivel pedestal base of the driver’s seat so whoever installed the tile must have removed the base and must have seen the obvious signs of damage.  They should have stopped right there and let someone know and CMI should have contacted us to discuss a course of action.  The obvious course of action would have been to pull up the top layer of plywood and see what was going on.  We would not have been happy about it at the time as we were already spending more money on fixing things than we anticipated, but we could have discovered and fixed this six years ago.

The floor directly under the base of the seat is the ceiling of the first bay on the driver’s side of the bus.  It was very chilly outside so I put on my hooded sweatshirt and had a look from below.  I could see that the four threaded holes for the seat mounting bolts were part of two large steel angles running fore and aft that were welded to two square tubular steel cross members.  From that observation I decided on how to proceed.

My plan was to cut out the bad plywood by cutting between the centers of the holes.  That would leave half of each angle to support a new piece of filler plywood.  I got the Porter-Cable oscillating saw and started cutting out the really rotten wood aft of the rear seat mounting holes.  I was not prepared for what I found when I finally got that piece out.

The damaged bus sub-floor cut away.  I could see through into the bay below the driver’s seat.  The blue to the left is paper shop towels soaking up the water and rotted plywood in a small tray area.

The damaged bus sub-floor cut away. I could see through into the bay below the driver’s seat. The blue to the left is paper shop towels soaking up the water and rotted plywood in a small tray area.

What I found was water; not dampness, but standing water.  And debris, lots of mucky debris.  We had a lot rain starting late Tuesday evening, all through the day yesterday, and overnight into early this morning so I suspected that this water might be “fresh” as in recently arrived in this location.

The cross member aft of the rear pair of seat mounting holes is the top of the rear wall of the compartment under the driver’s seat.  All of the water was in the area aft of the cross member in what appeared to be a kind of tray about two inches deep below the level of the driver’s floor.  It was almost full of disintegrated plywood, and other stuff, and obviously did not have a natural drain.  I sent a second  text message to Linda and Chuck with a photo of the water/debris-filled pan aft of the rear mounting holes for the driver seat pedestal.  Some things you just have to share, and some things you just have to see to believe.

It took me a little longer to realize what was going on as my immediate concern was cleaning up the mess.  I put on a disposable glove to pick up all the detritus in the tray and put it in a trash bag.  The tray extended under the floor towards the outside of the coach so I reached back in there and just kept pulling out more and more wet junk.  At this point I started to analyze what was in front of me.

It was now obvious to me that the damage to the floor under the driver’s seat was caused by water filling this tray and coming in contact with the bottom of the plywood bus floor.  With nowhere for the water to drain it was able to stay in contact with the plywood for very long periods of time allowing it to penetrate the plies, soften them, and destroy the (water soluble) glue between them.

Clearly I needed to figure out where this water is coming from and stop it, but that was not going to happen today.  I did, however, go back outside and check the front electrical bay.  Sure enough, there was a little water on the floor of that compartment, so it was possible that the water might be coming from there somehow.  If so, I need to find the breach and seal it.  That, however, just pushes the problem down the road as I will still need to figure out how water is getting into the electrical bay in the first place and stop that.

The more I studied the way the bus was built the clearer it became that the original plywood bus floor extends under the left console into the first bay and separates the small upper compartment from the larger one below.  But this tray-like area was below the floor and farther back which meant it was under the front electrical bay and above the driver side steer tire.  I will have to check again but it appeared that this piece of plywood must be the floor of the electrical bay.

With a better, but still incomplete, understanding of the situation I resumed cutting out plywood.  My oscillating saw went through the rotten wood like a hot knife through butter, but did not cut the undamaged plywood very well.  I figured the blade was dull so I opened the Bosch replacement blade I had on hand only to discover that it did not fit my Porter-Cable tool.  Arrrgh.

It was probably a good time for a break anyway, so I went to Lowe’s to get a couple of extra blades.  I had good QSOs with Mike (W8XH) going to and from the store.  The weather is supposed to be very pleasant all next week, with afternoon highs in the upper 60’s, so we are going to try to find a day to work on my antennas and the small tower next to the house.  Bus or no bus, I also have to make time for our amateur radio hobby.  When I got home I made popcorn for lunch and then got back to work.  It’s a good thing I don’t have to fix most of my meals.

Linda called at 3:15 PM to see if she needed to come home and pick me up before going to Ann Arbor.  Given what I was dealing with I was tempted to say ‘yes’ but I knew that this was a situation where I needed to stay on task until it was fixed.  Brendan and Shawna both had work-related obligations this evening and asked Linda if she could watch Madeline for a while.  Rather than have her cut her work day short to come home she left the bakery and drove directly to Ann Arbor while I continued to work on repairing the floor.

I called Chuck to see if he had time to consult with me about all of this.  He called me back and we talked it through.  He thinks the entry point for the water could be the frame on the large piece of fixed glass just aft of the driver’s position.  I know we have a leak near the front of the large window assembly just aft of that one and the forward edge of the window panel may also be above the front electrical bay.

As soon as I was done talking with Chuck I removed the reading light on the vertical walnut chase by the driver’s left shoulder and then removed the nine screws that hold the cover in place and took it off.  I have known for a long time that there was a lot of stuff running through that chase but I had never removed the cover to look inside.  It is crammed full of AC and DC wires, coaxial cables, air lines, and residential air-conditioning refrigerant lines.  My immediate interest was evidence of water, and I did find the same stains that were similar to ones we have found elsewhere in the coach, but I did not see anything that looked or felt wet.

With the new blade for my oscillating saw I managed to cut out the piece of plywood between the four mounting holes but it wasn’t easy.  With that piece out, however, I could use my inspection mirror to see the underside of the floor and reach into the space below to determine distances to various structural members with my carpenter’s tape measure.

I still had more wood to cut out but by 4:15 PM I’d had enough for today.  I set the top layer of plywood back in place and covered all of the larger holes with painter’s tape in a feeble effort to keep critters and cold air out of the coach overnight.  I also used two pieces of felt and painter’s tape to seal the hole where the steering column goes through the floor.  I took a few more photos, which I had been doing all along today.  Tomorrow I think I will use the circular saw and/or the cutoff tool and try to make quicker work of this.

Before quitting for real I decided to unscrew the 3-sided bump out from the passenger side HVAC duct cover and measure the left desk base and pedestal to see what the correct distance needs to be.  The bump out protrudes about four inches but it should only be three inches.  As I suspected it is too big by the width of the wood, but I will take more careful measurements before I take it to Jarel to have it cut down.  I also discovered, however, that the filter material we used to cover the hole where the heater hoses previously came out of the HVAC duct was interfering with the fit of the duct cover, including the bump out.  While I was thinking about it I pulled out the two filler strips that go on either end of the plywood sofa seat.  Jarel is going to remake them longer and out of solid walnut.  Since we moved the seat board out almost five inches one side of each strip is now exposed and visible and the stained plywood edge is just not the look we want.

We had a heavy overcast most of the day and by 5 PM the light was fading.  I dialed back the thermostats, grabbed the camera and the house phone, locked up the bus and went inside.  I changed into my robe and then fixed dinner.  I did not want to spend a lot of time preparing and eating a meal by myself so I had a can of Amy’s Chili with Vegetables.  I added crackers, Smoked Tabasco Sauce, and shredded Daiya mozzarella vegan cheese.  Some strawberry preserves on crackers added a touch of sweetness and Stash Raspberry Pomegranate Green Tea added its own warmth.  Given a little more time I can make a better meal for myself but ever since Linda retired and took over preparing our whole-food plant-based (vegan) cuisine I am no longer as comfortable/confident in the kitchen as I once was.  This way of eating involves ingredients and techniques with which I am simply not familiar.

After dinner I sat on the living room couch in the same spot, and in the same robe, as I did at the beginning of the day and worked on this post.  I like the sense of things coming full circle, but mostly it is a comfortable place to sit and use my iPad.  Linda and I texted for a while after she had put Madeline to bed.  At 9:07 PM she indicated that she was leaving Ann Arbor and heading home.  She got home a little before 10 and we sat in the living room for a while and finally turned in at 11.  It had been a long day for both of us.