Tag Archives: desk base heat exchanges (H3-40)

2015/10/13 (T) Desk Alignment

I got up at 8 AM, put on my robe, made coffee, fed the cats, and refreshed their water fountain while Linda got dressed and washed blueberries to put in our granola. We took our coffee to the living room where I turned on the fireplace and we were joined by our feline friends. I put the finishing touches on yesterday’s post and e-mailed it to myself while Linda pulled up the latest video post from Dr. Michael Greger at NutritionFacts.org.

Linda left at 9:30 AM to meet Diane at Kensington Metropark for their weekly walk. As this will probably be their last walk together until spring they planned to go to lunch afterwards. While there was some work I could do by myself on the (permanent) installation of the desk there were other aspects of the job that would definitely require two people. I needed to finish updating the roster for the FMCA Freethinkers chapter so I spent about 30 minutes reading the manual for the new Sony SLT-a99v camera and then got dressed and worked in my office for the rest of morning.

After a short lunch break I resumed working on the roster until Linda got home. She and Diane had lunch at Baker’s in Milford as it is close to the Metropark parking lot where they meet. We removed most of the things from the bus we were not currently using, many of which were stored in the sofa storage box. We got the sofa seat off of the desk pedestals and set it back in place on the sofa base.

I wanted to use pieces of a 24″ X 30″ furnace filter to cover the various air inlets in the desk bases and the air outlets in the OTR HVAC duct. The best way to hold the filter material in place appeared to be with some very strong tape. We did not have any such tape on hand so Linda went to Lowe’s and bought a roll of Gorilla Tape while I cut pieces of filter material to fit the various openings.

The left desk base and passenger side OTR HVAC duct showing the pieces of furnace filter material used to seal these openings while permitting filtered airflow.

We got all of the openings taped up but I still needed to fabricate two tongue and groove alignment devices between the pedestals and the center connector/cover. I make these out of flat mending plates, one on the pedestal (tongue), and two on the connector/cover (groove). The tongue is flat against the back side of the pedestal vertical board and protrudes about 1/2″ beyond the edge. The groove is made from two plates, one stacked on top of the other, attached to the back side of the vertical connector/cover board. The upper plate is just back from the edge of the board and the lower one (next to the wood) is offset from the edge a little more than 1/2”, just enough to create a space for the tongue. The tongue and groove devices match two others lower down on the connector/cover. All four of them are oriented vertically allowing the connector/cover to drop into place and force it to align with the matching pieces of the pedestals. A pair of horizontal plates, one on each pedestal, provide a resting surface for the connector/cover that aligns it horizontally.

With the devices fabricated we were finally able to set the pedestals on the bases, drop the connector/cover in place, and align everything as if the entire desk was a single unit. We then got the Corian desktop out of my car, brought it into the coach, and set it in place. It will require some careful adjustments before we screw everything down but it basically fit properly and looked good. Final positioning of the left pedestal and base, however, would require us to put the front HVAC duct cover in position.

We got the cover out of the library and into the bus for the first time since we brought it home from Jarel Beatty Cabinetry in Logansport, Indiana. The length was perfect but the bump out where the heater hoses were originally going to loop through was too deep. I suspect the mistake was in my design/drawings. Jarel knew this piece was supposed to line up with the left pedestal and base but I no longer recall if he even had the desk pieces in his possession when he was building the cover. At this point it didn’t matter anyway. The misalignment is with the base and is not very visible. Also, the bump out is screwed on to the main cover so it can eventually be removed and trimmed or replaced with one that has the correct dimensions.

Once we had the cover in place I realized that I also needed to fabricate and install alignment plates between the cover and the left pedestal. I had not planned on this and did not have enough mending plates so we went to Lowe’s to buy more. While we were there I bought another can of 40:1 premixed fuel and a bottle of bar and chain oil for the new Poulan Pro 18” chainsaw. We stopped at Walmart to see if they stocked a particular folding chair made by Stakmore that we have seen online, but they did not. We think it would work nicely as a desk chair, and go well with the interior materials and colors in our bus, but we would like to see one in the round before buying it.

Back home I worked on the alignment plates while Linda prepared dinner. We had leftover lentil loaf, microwaved sweet potatoes, and a mix of steamed broccoli and Brussels sprouts. She added a little water to the lentil loaf before reheating it to moisten it a bit. We both like ketchup on our lentil loaf and I added some Pick-a-Poo sauce to mine. All three dishes were served hot, which was comforting on a cool evening, and everything was very tasty including the cup of hot tea.

I returned to the bus after dinner and finished installing the mending plates on the HVAC duct cover. I was not able to put it in place by myself, and there was no reason to have Linda come out and help at this hour, so I set the thermostats back and locked up the bus.

I called Butch and this time the call went through. I updated him on the installation and testing of the fan-coil heat exchangers and asked him about the operation of our new refrigerator. He suggested that I isolate the remote temperature sensors by using pieces of the furnace filter material to keep them from touching an objects or surfaces directly. He and Fonda are wrapping up at the RV Park in Bouse and moving to Quartzsite on Thursday. After we were done talking I worked on this post while we watched a few TV programs and then went to bed.

2015/10/11 (N) Now Heat This

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I guess we were tired after having Madeline at our house for 23 hours. We slept in until after 8 AM and it was going on 9 by the time the coffee was brewed and we sat down to breakfast. I really needed to attend to some paperwork for our FMCA Freethinkers chapter but was also eager to get deeper into the manual for the new Sony a99v camera. I installed the PDF manual onto my laptop yesterday from the CD-ROM that came with the camera and then e-mailed it go my iPad2 so I could read it conveniently.

HL – Jasper, our mackerel tabby male cat, allows himself to be photographed on the living room floor. You wouldn’t know it from this photo, but he is actually a very sweet animal ad a real joy to have in our household.

Jasper, our mackerel tabby male cat, allows himself to be photographed on the living room floor. You wouldn’t know it from this photo, but he is actually a very sweet animal ad a real joy to have in our household.

Other than the time, date, and date format I have not adjusted any of the default settings or experimented with the camera’s many functions. I have taken a few photos just to make sure it works but I do not want to start generating a lot of image files until I have made decisions about basic things like folder naming conventions and “normal” shooting modes and settings. I did, however, enable a “rule of thirds” grid on the viewfinder screen.

Linda worked on our personal accounting and then prepared the treasurer’s report for our amateur radio club meeting this evening. I took a break from reading the camera manual to research the availability of some accessories on the B&H Photo website.

The electric cable release for my old Minolta 9000 SLR film cameras works with the a100 so it may work with the a99v too. If not, newer remotes are available, including wireless ones that are not too expensive. I found the angle finder but it is discontinued. With the adjustable LCD screen in the back of the camera the angle finder isn’t really necessary but would have been a nice accessory just the same. I am also looking for a case and/or a photographer’s vest and/or a chest harness/holder. The a99v with the vertical grip and a telephoto lens is a substantial piece of equipment, both in size and weight, and the chest harness/holder would support that weight more comfortably and securely than a neck strap. I found several interesting things but not exactly what I had in mind.

By the time Linda finished her accounting tasks I was dressed to work. First up was the hydronic heating system in our bus. I got four pieces of 2×4, each about four feet long, and two pieces of 2×12 about 16″ long. I put a pair of 2x4s under each desk base and inserted one of the 2x12s between the 2x4s and the base. That raised each base three inches which was enough to ensure that the heater hoses attached to the lower fitting on each heat exchanger sloped slightly downward back towards the main unit.

The hose that connects the two heat exchangers together in series is attached to the top fitting on each one. Half way between the exchangers is a T with the bull branch pointing up. A ball valve with a waste port is attached to the branch. While Linda held the valve higher than anything else in the system I opened the valve and used a small funnel to slowly pour in antifreeze. When the lines and exchangers appeared to be full I closed the valve, turned on the thermostat for that loop, and turned it up to cause the circulating pump to come on. I let the pump run for a few minutes and then turned it off. Again with Linda elevating the valve I opened it and added a little more antifreeze. I ran the pump again for a few minutes and shut it off. This time the coolant was still right at the valve so I shut it and Linda set it down.

It was now time for “the big test.” In order to be able to see if there were any leaks, and catch any coolant if there were, we put heavy duty paper shop towels under all six of the clamped connections where the heater hose went over 3/4″ copper as well as under the soldered joints of the T and valve. I opened the water bay on the passenger side, where the Aqua-Hot is installed, checked the coolant level in the expansion tank, and made sure the paper cup was positioned under the overflow tube. The level of coolant in the expansion tank was just above Minimum Cold. With everything in order I turned on the Aqua-Hot burner and then turned the front zone thermostat back on. I also turned on the thermostats for the bathroom and bedroom zones to cause coolant to circulate through those loops.

There are quite a few gallons of antifreeze in the hydronic heating system and even on a mild day such as today (temperature just above 70 degrees F) it takes a while to heat it up to the 170 degrees required to shut off the diesel burner. I kept checking the hoses by the fill valve and the expansion tank. When the hoses were warm and the level of the coolant had risen 1/2″ in the expansion tank I cracked open the waste port on the fill valve. I got a tiny, short hiss and then coolant came out so I quickly closed it. It appeared that our method for filling the system and bleeding the air out had worked as intended, and there was no evidence of any leaks.

I left the Aqua-Hot on until it shut off on its own. The expansion tank was near full at this point and I topped it up. As the system cools down the coolant will contract in volume and some of the coolant in the expansion tank will be drawn back into the main chamber. It’s important that there is more coolant in the expansion tank than the amount that will be drawn in or air will get drawn in instead. I buttoned up the coach and turned to my next task.

I removed the chain from the new Poulan Pro 18” chain saw since I completely dulled it trying to cut through a tree root. As long as the cover, chain, and bar were off I cleaned up the motor unit as best I could. Oil impregnated sawdust is tenacious stuff. I put the new chain on the bar and attached them to the motor, making sure the chain was oriented correctly. I topped up the bar and chain oil reservoir and topped off the fuel tank.

It took several trips to get the 7′ step ladder, pole saw, compound lopping shears, hand tree saw, and chain saw back to the apple tree. I noticed yesterday that one of the main branches coming off the trunk about 3′ above the ground was dead. The bark was missing and the smaller limbs were brittle. The bark looked like it might have been chewed away by deer but I wasn’t sure. All I knew is that it was dead.

I started with the pole saw and worked from the ladder to cut off the limbs that extended far up into the tree. Once I had those detached and pulled out of the tree I started the chainsaw and used it to cut off the larger branches as I worked my way down towards the main trunk. I gathered all of the smaller material into a pile and then gathered the larger pieces together. I used the largest piece as a sawbuck to support the other pieces as I de-limbed them and cut them into four foot lengths. I then cut up a large pine tree limb that has been sitting on the ground under the apple tree for quite a while. I used the pole saw and loppers to trim off a few other small branches and the carried all of the tools back to the garage. It was 3 PM by the time I got everything put away. I was done with physical work for the day so I got a much needed shower and got dressed appropriately for our meeting later.

The apple tree is still in need of serious pruning if it us to survive and bear useful fruit. It particular it needs to be “topped.” It is too tall overall, especially in the center, and much of the fruit is growing up there where the sunlight is good but it cannot be reached either by us or by the deer. We have been putting deadwood in the firepit all summer and, more recently, on the disposal pile, where it goes mostly depending on what part of the yard the tree was in when it fell or got cut down. In the case of the apple tree it occurred to me that Applewood is prized for the smoke it produces when grilling so I may stack it up, let it continue to dry, and perhaps rent a chipper next year to turn it into something useful.

We had breakfast later than usual, and skipped lunch, so we ate dinner at 4:30 PM, which was earlier than usual. Dinner was lentil loaf, baked potato, and steamed broccoli, a simple but healthy and tasty meal.

On Friday I exchanged a few text messages with Josh at Coach Supply Direct regarding our desktop and table. The net result was that his schedule had changed and he was not going to be able to get our desktop and table from Countertops Plus in Shipshewana, Indiana and deliver them to us for over a week, at the earliest. He had also planned to bring some extra clips for our MCD shades and look at the wiring on the front passenger seat 6-way power base. Those last two items were not critical but we are ready to install the desk once we have the desktop and cannot afford to wait another week and a half to get it. I called and left a message for Ferman Miller to let him know I would be driving down tomorrow morning to pick them up. I then worked on this post until 5:30 PM when I stopped to reinstall the antenna, radio, and GPS in my car.

We left at 5:45 PM for our monthly SLAARC meeting and shortly thereafter heard Mike (W8XH) on the South Lyon 2m repeater. I replied to his call and we had a QSO that lasted almost all the way to our meeting site, where we arrived within a minute of one another.

We socialized with fellow club members from 6:30 PM until Harvey (AC8NO) called the business meeting to order just after 7 PM. The club secretary was absent so I took the minutes. The business meeting lasted less than 10 minutes and was followed by a presentation on APRS by Eric (K8ERS). I gave Mike (W8XH) a check for the Icom IC-2820H dual band radio that has been in my car since early summer.

As I said at the beginning, I really needed to update the FMCA Freethinkers roster and financial reports and make them available this evening. Well, sometimes things don’t happen just because they need too. Today was just too perfect a day to waste it sitting inside at a computer and by the time we got home from our meeting I did not feel like starting this task. I will try to make this a priority tomorrow evening, but each day is an adventure and I have to be agile in dealing with the myriad tasks that lay before me, including ones that appear unexpectedly.

2015/10/08 (R) A Mighty Hose

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Linda was up before 6 AM to drive to the bakery ahead of the worst of the morning rush hour traffic. I was aware of her getting up but fell back asleep. She is very quiet as she goes about her preparations on such mornings, which I appreciate.

I got up around 8AM, fed the cats, and cleaned their litter tray. I made half as much coffee as usual and measured out a bowl of granola, probably a little more than usual. I took my coffee to the living room and turned on the fireplace, expecting to settle in with my cats and work on my iPad, but the iOS 9.0.2 update was available so I started the installation and read the last few pages of Number Theory and Its History by Oystein Ore. I read from screens more than from paper these days, but I still like to curl up with a printed book.

Jasper used to sit next to me on the sofa in the morning but seems to prefer sleeping on top of one of the back cushions these days. Juniper, who never used to pay much attention to me, has taken his place. She has always sought out warm places to curl up but has always preferred Linda’s lap to mine.

My bus project for today was reassembling the plumbing to the two fan-coil heat exchangers that go in the bases under the two desk pedestals. Yesterday I cut new holes for the supply and return hoses. My first task was to remove the hoses from the bleeder valves and install barbed plastic plugs in the ends to prevent coolant from coming out. I then pulled the hoses back and out through the new openings.

The area behind the desk where the heater hoses emerge from the passenger side OTR HVAC duct.

I worked on the hose for the right hand (rear most) heat exchanger first. I positioned the base, routed the hose to the lower fitting, and marked where to cut it. I put a plastic paint tray liner under the hose before I cut it but more coolant came out than I expected. I got as much of it in the liner as I could and grabbed a bunch of paper shop towels. I got the liner outside without spilling any antifreeze and poured the used antifreeze in a one gallon jug that I keep for just this purpose. I used a funnel that is also reserved for use with antifreeze.

I took the cut off piece of heater hose outside, plugged end down, and set the open end in the tray liner. We already had a bucket of soapy water in the bus as we had planned on hanging wallpaper yesterday. I wrung out the sponge and then squeezed some of the soapy water on the floor and cleaned it up with paper shop towels.

The left and right desk bases and center cover/spacer set in place. The heater hoses are not yet connected.

With the mess cleaned up I slipped two hose clamps over the end of the hose and worked it onto the lower fitting on the heat exchanger. If only it had been as easy to do as that description! The 3/4″ i.d. rubber heater hose did not just “slip” over the 3/4″ o.d. copper pipe even with some residual antifreeze lubricating the inside of the hose and the outside of the pipe. Indeed, it took considerable and simultaneous pushing and twisting to get the hose on. It was also a lot harder than I expected to work with the heat exchangers installed in the bases, even without the desk pedestals in place.

I was interrupting my work as needed to take photographs and as I finished up the first hose the camera refused to trigger the shutter. The LCD screen indicated that the compact flash memory card was full so I went to my office to offload the images from the last few days. My other CF card was empty so I put that in the camera and set it aside. I had not backed up my photos to the Network Attached Storage units in quite a while so I decided to take the time to do that. While I was at it I backed up my blog posts from December of 2014 through July of this year along with several issues of The Gypsy Journal.

As long as I was at my computer I checked my e-mail accounts, logged into RVillage, and logged into my account at B&H Photo. My new Sony alpha 99 and accessories were on their way from New York and due to be delivered by the end of the day tomorrow. I am excited to finally be getting a new digital camera with a full frame (35mm) sensor that will work correctly with all of my old Minolta A-mount lenses.

By this point it was lunchtime so I cleaned up (antifreeze is definitely NOT good eats) and scrounged around the kitchen for something tasty but easy to fix. My “go to” meal is usually roasted red pepper hummus and sourdough pretzel nibblers. We had a little hummus left, which I finished, but I was still hungry so I made a bowl of popcorn. I would probably not make a good bachelor.

I went back to the coach and contemplated attaching the other hose to the left heat exchanger. While I was thinking about it Linda called to let me know she was on her way home. It was 1 PM so I decided to wait for her to get home to help me install the second hose. I had some phone calls to make and used the time for that.

I called Karen at Bratcher Electric to schedule the upgrading of our 60 Amp sub-panel in the garage to a 100 Amp main panel. While I had her on the phone I asked if Mike would itemize the quote. I also mentioned that they had picked up two or three whole house generator customers through my referrals and perhaps Mike could provide some consideration for that in the pricing. Next I called Ferman Miller at Countertop Plus in Shipshewana, Indiana to check on the Corian desk top and table. Ferman answered the phone and said he had called Josh this morning to let him know the pieces were ready for pickup. I then called Josh to see what his plans were.

We originally agreed that he would pick them up and bring them to our house on his way to visit relatives in the northeast side of the Detroit metropolitan area. His plans had changed and he won’t be visiting his relatives anytime soon. He is leaving on Tuesday for a FMCA area rally in the Carolinas and will be gone for a week. Before he leaves he needs to get something to a customer in Cleveland in addition to getting our stuff to us or deciding that we will have to drive to Shipshewana to get it ourselves. One option is that we meet him somewhere on Sunday. Ann Arbor is a possibility but Toledo or Defiance (Ohio) are more likely rendezvous points.

Linda got home around 2 PM and changed into her work clothes. With Linda’s help I was able to avoid the mess I had with the first hose. The second hose was even harder to get on than the first one but we managed to do it. In part because of the arthritis in the joints at the base of my thumbs I do not have as much grip strength as I would like and often need. The twisting and pushing was hard on my hands and the confines of the base and proximity of crisp wooden edges resulted in lots of small cuts. This was not something I anticipated in the design and construction of the bases and the installation of the heat exchangers.

I took a break and drove to Northwest Plumbing Supply to see if they had a bleeder valve like the ones in our bus system. They did not and had never do seen anything like it before. The showed me a couple of things they did have but I did not buy anything. I got a call from Brighton Honda that my car was ready for pickup so I headed home to get Linda. She drove me to the dealership and then went on to Meijer’s for a few grocery items.

I drove to Lowe’s in Howell and was fortunate to find Lars in the plumbing department. The store was not very busy and he took an interest in showing me various plumbing options that might allow me to replace the bleeder valve with something that would do the same thing while also giving me a way to add antifreeze to the system. What I ended up with was 3/4″x3/4″X1/2″ copper sweat T and a 1/2″ sweat ball valve with a waste port.

Bruce works on attaching the heater hoses to the fill/bleeder valve T assembly he built. (Photo by Linda.)

Back home I cleaned some 3/4″ and 1/2″ copper pipe with 120 grit plumbers sandpaper. I cut two pieces of the 3/4″ pipe about 3″ long and one piece of the 1/2″ pipe about 1-1/2″ long. I brushed the inside of all the fittings and test fit the pieces. I then applied flux to all of the surfaces to be soldered, inserted the two 3/4″ stubs into the run fittings, inserted the 1/2″ stud into the bull fitting, and put the ball valve on the other end of the 1/2″ pipe. I used the lever on the ball valve to mount the assembly in my bench vise. I removed the waste port cap to protect the neoprene seal and opened the ball valve so as not to trap heat inside. I then heated the T and the end of the valve and applied the solder.

I figured there had to be an easier way to get heater hose onto the heat exchanger and that Butch was the guy who would know what it was. I called and he said antifreeze can obviously be used and works fairly well but that a small amount of dish soap would also work as a lubricant and not harm the antifreeze or the Aqua-Hot and its components. As long as we were on the phone I caught up on their activities.

They were still there at the RV Park in Bouse, Arizona but only until the 15th of this month. The terms and conditions of their employment as managers of the park had not turned out to be as described during the interview process and they are wrapping up after only a month on the job. They will move their bus back to Quartzsite and spend at least part of the winter at Joe and Connie’s place where we both spent last winter. I know it was a big disappointment to them that the situation in Bouse did not work out, but their situation in Q will be familiar, comfortable, and inexpensive, as well as convenient to the Quartzsite Gem and Mineral Club which they joined this past winter.

For dinner Linda made a blend of onions, garlic, mushrooms, and power greens and served it over a baked potato topped with Daiya cheese. It was very yummy, and the potatoes kept the dish warm all the way to the end. The weather had turned cloudy through the afternoon and we got the first raindrops during dinner.

The fill/bleeder valve T assembly with the heater hoses connected. The assembly is located between the bases at the floor and will be hidden by the center connector/cover.

I had really hoped to have the hydronic heating system reassembled today so we went back out to bus after dinner to hook up the heater hose that runs between the two heat exchangers. This was actually two pieces of hose with my homemade bleeder/fill valve half way between the two exchangers. Even with dish soap the two hoses were very difficult to get onto the heat exchanger fittings and the bleeder/fill stubs, but I got them on. Linda took pictures while I grunted, groaned, and moaned and I took a few more when I was done.

It was 8:45 PM when we finally quit working, secured the bus, and went inside. I cleaned my hands as best I could but I could not get all of the black from the rubber hoses to come off. We sat for a while in the living room and had the last of the frozen chocolate torte that Linda made a couple of weeks ago. We finally turned in around 10 PM and watched Rick Steve’s Europe, Travel in the Americas, and a couple of cooking shows while I worked on this post.

2015/10/07 (W) The Root Cause

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We had Linda’s homemade granola for breakfast with fresh blueberries. Berry season is just about over for the year and they will become more expensive as they have to be transported from farther away. I made a pot of Sweet Seattle Dreams, the half-caff blend that Jeff makes just for us, and we drank it in the living room. Linda checked in on the world and pulled up the latest video from NutritionFacts.org while I researched hardwood veneers on Rockler.com.

After breakfast and coffee I called Metro Environmental Services to arrange to have the culvert under the road cleaned out. They were able to schedule us for this afternoon so I accepted that appointment. I then called Brighton Honda to check on my car and left a message for Rob, the service advisor who wrote up the repair for the driver side door lock. I had no sooner left that message than I got a call from Karen at Bratcher Electric.

Mike had worked up the quote to install the 100 Amp disconnect, tie it into the output of the transfer switch, and run a 100 Amp 4-wire service entrance cable to the current sub-panel, making it into a main panel. They would also disconnect and cap the current sub-panel feed from the basement as part of the work. At just north of $1,300 it was a good $300 higher than I expected. My expectation, however, was not based on anything specific other than my own sense of the cost of materials and the amount of labor that might be involved, plus a desire for it to not cost more than $1,000. 🙁

With the phone calls taken care of we worked in the bus for the rest of the morning. Linda worked on stripping the remnants of wallpaper that remained after we removed the mirrors from the lower outside hallway wall yesterday. I worked on re-routing the heater hoses for the fan-coil heat exchangers. She got her job done before I got mine done. That’s usually the way it is.

To start, I removed one of the old 4″ round plastic grates and used my inspection mirror and a flashlight to examine the inside of the HVAC duct. What I discovered was that the two heater hoses were secured periodically with plastic cable clamps to the outer wall of the HVAC duct. I also discovered that the metal part of the duct is just the inner wall and top. The bottom is the plywood subfloor of the bus and the outer wall is the plywood wall. As originally built the metal portion of the duct could be removed but when Royale Coach did the conversion they built cabinets around the ducts and put wood wiring chases on top of them in such a way that they can no longer be removed without partially disassembling the coach.

The location of the hoses and wires in the duct was such that I could safely use my 4″ bi-metal hole saw to cut access holes for the hoses. I determined where the cable clamps were located by measuring inside the duct. I then marked where the access slots in the bottom back of the bases would be located and determined where I needed the two hoses to emerge from the duct.

The manual sheet metal nibbler used to cut a line between the bottoms of the two holes in the HVAC duct.

There was already a 4″ hole at one of my needed locations so I drilled a second one next to it with an inch in-between. I used Chuck’s hand powered sheet metal nibbler to connect the holes together to make an opening that looked like the track around a football field. We vacuumed up the metal chips and I then installed door edge molding all the way around the edge of the opening. I was able to reach the screws holding the first pair of cable clamps with a #2SR screwdriver and remove them. This large slot will be behind the left end of the center connecting cover of the desk and the hose for the heat exchanger that goes in the left base will come out of it.

Plastic U-channel door edge molding installed around the new heater hose opening.

The location of the next pair of cable clamps corresponded, roughly, to where I needed the hose for the right heat exchanger to emerge. I drilled two 4″ holes, side-by-side, at that location and nibbled out the little bit of metal in-between them to make a second slot. Again, I installed the door edge molding around the entire edge. The molding was a tight fit, and I had to use a screwdriver to get it to go on the inner curves, but I got it on. The U-channel is locked in mechanically and has adhesive in it so it should stay put once it has had a few days in place. Once the hoses are re-routed I will put screen material, and perhaps some solid plates, over the openings to prevent critters from gaining access to the living area by way of the HVAC PCTS (Prevost Critter Tunnel System).

The access holes in the OTR HVAC duct in the area behind where the desk will be installed.

Linda had two medical appointments this afternoon, both routine diagnostic procedures, so she got cleaned up, changed her clothes, and left around 12:30 PM as I was finishing up the second slot. I went inside and was thinking about making something for lunch when the doorbell rang. It was our mail carrier, Michelle, with a package that was too big for the mailbox. A few minutes later the doorbell rang again. I figured it was Michelle again, but it was one of the guys from Metro Environmental Services. They were supposed to call first but just showed up.

I put my shoes on and walked them down to the clogged culvert that goes under the road. I was really hoping they could clean it out from the south side but when we went into the woods we could not see the end of the culvert. They got a metal detector and located the end of the pipe. It was almost completely buried and had a massive root running right in front of it from a very large nearby tree. They got a shovel and dug out around the root, exposing much of it and the end of the pipe.

The tree was probably 30″ in diameter at the base and the root was at least 10″ in diameter. I got my (new) 18″ chain saw but had trouble getting it started. It turned out it was out of gasoline. Once I got it started I tried to cut through the root on either side of the culvert. I thought I was all the way through on one end (closest to the tree) and most of the way through on the other end, but the root would not budge. I dulled the teeth on the chain to the point where the saw would no longer cut and did not want to take the time to put a new chain on just to ruin it quickly. The guys finally agreed to hydrojet the culvert from the north side of the road.

The actual cleaning out of the culvert did not take that long. The pump produces 2,000 PSI and they used about 300 gallons of water from the onboard tank on their truck. The head on the end of the hose has one forward facing nozzle and many rear/side facing nozzles. The forward facing nozzle loosens and cleans out the area directly in front of the head while the other nozzles force the head forward and blast whatever is in the pipe back out towards the entrance.

They started with a small head and ran it in until there was water coming out the other end of the culvert. They then pulled the hose back and switched to a much larger head and ran that all the way through and back. When they were done muddy water filled the culvert and the depressions on either end. On the inlet end the water was only about 3″ deep in the bottom of the culvert but on the outlet end it was near the top. They billed me for the minimum first hour amount even though I think they were here longer than that.

I called Phil to let him know what we had run into. He was surprised, to say the least, as he thought he had checked the other end of the culvert. Obviously not, but that’s water under the road, so to speak. Besides the problems with the root and the discharge end of the culvert being below the surface, it looked to me like the discharge area was something of a low spot and it was not obvious to me where water would flow from there. I have learned, however, that I am not very good at judging such things visually.

Cory, our neighbor across the street, had come over to see what was going on. He offered that the discharge area does, in fact, drain to the south through his property and eventually to Golf Club Road. Cory has been here for 30 years so I have no reason to doubt the truth of that. The elevation where Golf Club ends at Hacker and where our street ends at Hacker appears to be about the same. Our street is fairly level while Golf Club has a little bit of up and down, but it is subtle. I suggested to Phil that we might have to clear a path into the woods for his small digger and do some trenching to give the water a way out.

While Cory and I were chatting I noticed that the trees along this part of the road were hanging out over the road on both sides and were rather lower than they should be. This is the very thing I complain about with regards to the way most of our neighbor’s fail to maintain their properties along the road. I decided I should do something about it so I got our pole saw and spent a couple of hours trimming the low overhanging branches.

Linda went to the Whole Foods Market in West Bloomfield following her medical appointments and got home just as I was finishing up the pruning. She went for a walk while I called John Palmer of Palmer Energy Systems in Florida. I bought our Magnum inverter/charger for the bus from John along with various accessories and batteries. I needed a 4-wire terminal block for our Magnum Battery Monitor Kit (BMK) because I had messed up the one that came with it when I originally installed it. John confirmed that Magnum Energy had recently been acquired by Sensata, and was in the process of relocating the plant to Minnesota, but that several of the old-timers were still on board. John needed to talk to Tom anyway and asked me to call him back in a week to see if he was able to get the connector.

I checked with the service department at Brighton Honda again and Rob said he expected to get the new door lock mechanism back from the locksmith tomorrow morning and to have the car ready for me to pick up by the end of the day. It will be nice to finally have it back.

The cloudy weather finally broke today and we saw some blue sky with brighter light levels than we have had recently. The day was lovely but a little on the cool side by late afternoon so we both had a cup of hot tea. Linda took advantage of the light to work on her counted cross-stitch project, a holiday stocking for grand-daughter Madeline, and I went back to the bus to sand off the last traces of the old wallpaper from the outside wall in the hallway.

I used our Porter-Cable 1/4 sheet palm sander with 80, 120, and finally 220 grit sandpaper. The sander has an integral dust collection bag but it does not capture all of the dust. I used the vacuum cleaner to pick up as much of the residual dust as I could and then used a tack cloth to wipe down the wall.

For dinner Linda made pan-grilled tofu with caramelized onions in sweet barbecue sauce. She served it open-faced on rye bread, because that is what we had, and steamed some fresh green beans as a side dish. Yum.

After dinner I drove to Lowe’s. I needed something I could use to plug the two heater hoses to keep them from leaking as I pull them back through the HVAC duct and out through the new slots I made for them today. I ended up buying two 3/4″ barbed plastic plugs. While I was there I looked to see if they had any bleeder valves but they did not. They do not sell parts designed specifically for hydronic heating systems and I will have to go to Northwest Plumbing and Supply for such items.

While I was in the plumbing isle I looked to see if I could figure out some combination of parts to make a fill valve for the system but did not see anything that inspired me. I would love to have one or more high point expansion tanks on this system but I do not have any easily accessible places for them from which I could also run overflow drain lines. There is a good sized volume of unused space behind the drawers on the passenger side of the bedroom but it would be a very difficult place to install anything. Perhaps Northwest Plumbing and Supply will have something.

On the way home I stopped at the BP station and topped up the fuel tank in Linda’s car. I drove home with greater consideration for fuel economy than usual and managed to get the average MPG up to 56.7 before it dropped back to 55.4 as I pulled in the driveway. It will drop into the upper 40s as soon as Linda starts the engine tomorrow morning but it was fun to get it into the driveway with numbers above 55 MPG.

2015/09/23 (W) Autumnal Equinox

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We were up at 8 AM, had granola for breakfast, and enjoyed our coffee in the living room by the fireplace. I like cool mornings.

I spent some time yesterday morning, and again this morning, considering my full-frame DSLR options. The only 50 MP “35mm” DSLR camera body on the market at this time is the Canon 5Ds/R and there is no indication that Sony plans to introduce a successor to the A99 anytime soon. The A99 is still available, as is the vertical battery pack/grip and I am at the point where I will probably order one. It has a 24 MP full-frame CMOS sensor, which is double the resolution of my alpha 100. More importantly, it will accept all of my old 35mm Minolta A-mount lenses and they will work as designed.

Linda left at 9:40 AM to meet Diane at Kensington Metropark. I gathered up the laundry, sorted it, and started the first load. I then settled in at my desk for a while.

I e-mailed Mike (W8XH) to see if he could assist me on Saturday and/or Monday with climbing the tower to do some more antenna work. I then e-mailed Bill Gerrie to see if he and Karen were in Michigan yet. I pulled up the initial mockup of the October 2015 issue of Bus Conversion Magazine and proofread my article on replacing the speedometer. Jorge had done a good job of laying it out. I e-mailed back four minor corrections, one slightly larger one, and a general comment about the lack of space following periods. I had an e-mail from Steve Smith (N8AR) with contact information for Yaesu Fusion technical support.

The washing machine beeped so I transferred that load to the dryer and started another one. I noticed that it was after 11:30 AM so I cleaned the cats’ litter tray, grabbed the garbage from under the kitchen island sink, put it in the trash can, and got it to the street. Alchin’s normally comes “around noon” but I had a feeling they had already driven by. They were still in our subdivision, however, and stopped on the way out to empty our can.

I had another cup of coffee and updated this post. By noon Linda had not called yet let me know she was on her way home so I headed to Lowe’s for a roll of plumber’s sandpaper. I also picked up the paste we need to hang the new wallpaper. On the way back to the house I stopped at Teeko’s Coffee and Tea to order some Cafe Europe half-caff blend. Linda was home when I got back and we had a light lunch. We have both finally taken off some of the weight we put on this past winter. Long, hard work days with little or no lunch seem to help.

By the time we got back to work on the bus projects it was 3 PM. It’s hard to make progress when the workday starts in the afternoon. Today is the autumnal equinox, so it gets dark much earlier in the evening than it did in late May, June, July and even most of August. Still, as anxious as I am to get the heat exchangers re-installed we have to deal with the wallpaper in that part of the bus first. Linda helped me assemble the right desk base, repeating what we did yesterday with the left base.

The left pedestal base with the Aqua-Hot fan-coil heat exchanger mounted inside.

We installed the metal grates on the air openings (from the inside) and then used doubled-sided tape to affix the plastic mesh to the metal grate. We put a 1/2″ plywood spacer in the bottom and marked the locations of the mounting bracket holes and the heat exchanger. We took the exchanger and spacer out, punched the starter holes, and drilled. Linda cleaned the heat exchanger and used a pair of tweezers to straighten the bent radiator fins, of which there were quite a few. We cleaned off the two copper pipe stubs that provide the inlet and outlet for the antifreeze and then attached the self-stick 3/8″ X 1/4″ dense foam weather-stripping around the front of the housing. We mounted the exchanger to the spacer with approximately 1/8″ of the foam weather-stripping beyond the front edge of the spacer. We put the spacer/exchanger assembly back in the base and I secured it with screws while Linda pulled it into position, compressing the weather-stripping.

Linda cleans and straightens the fins on one of the fan-coil heat exchangers.

I took a few photographs as we worked and took some more of the finished assemblies. While we were working we got a call from Philip Jarrell of Precision Paving. Phil was calling to see if we still wanted the French Drain and driveway work done. He has been busy all summer and even more so coming into fall when folks decide they need stuff done before winter. He had given us a quote (estimate) back in the spring but could not do the work then because the soil was way too moist. The property has dried out nicely over the last seven weeks and he wanted to make sure he did the work yet this year if we were still interested. I told him “yes” and he said he would call “Miss Dig” right away to get the utilities marked and then get started.

The two desk bases with the fan-coil heat exchangers installed view from above and behind.

I think this annoyed Linda as it will be another significant expenditure, but it’s something I think needs to be done and it is not easy to get a slice of Phil’s time. (Actually, we have done a lot of difficult work together on the bus this summer and I think she was already annoyed from working with me on the right base.) Not taking advantage of Phil’s availability would likely mean a two-year delay in getting this work done.

This project is actually a combination of two different projects that happened to make more sense to do at the same than at separate times. The French drain is intended to dry out the far west end of our property which has standing water in the spring and after heavy rains, and stays moist/soft for the first half of the summer. There are a lot of trees in that area and we have lost some and are losing others. The driveway work will give us additional parking for people visiting in their RVs and create the main approach to the location for the bus barn that I hope to eventually build. The topsoil that Phil pulls out from the driveway will be used to fill in low spots on the west end of the property, further improving the drainage in that area.

The right desk base viewed from above/behind showing the fans mounted on the back side of the heat-exchanger.

Linda returned to stripping wallpaper in the bus while I folded the laundry and put it away. For dinner we had a salad and more of the soup that Linda made yesterday. After dinner Linda researched wallpaper installation while I worked at my computer and uploaded eight blog posts from the third week of July. About the time I finished the last one Brendan called so I went upstairs and Linda put the call on speaker. He is a couple of weeks into his position at Eastern Michigan University teaching Art History and gave us a status report on how it is going, along with news of how Madeline is doing in her new daycare program University of Michigan.

We watched Dr. Michael Greger’s 2015 nutrition research summary on Linda’s iPad. This is an annual presentation that he does at the vegan Summerfest in Pennsylvania. His theme this year was the top health concerns of Americans, based on a major survey that was done by one of the national survey organizations, and what nutrition research has to offer with respect to these. As we already know, many different diseases, one common answer; whole-food, plant-based, nutrition with no animal products. We really are what we eat, and Americans are now some of the least healthy people on the planet. We went to sleep reaffirmed in our dietary choices.

2015/09/22 (T) Bench Work

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Linda scraps the old wallpaper off below the passenger side living room window.

We were up at 7:30 AM and had fresh grapefruit and cinnamon raisin toast for breakfast. We turned the fireplace on and drank our coffee in the living room. After taking care of a few chores we got to work on the bus. Linda started stripping the old wallpaper while I finished soldering two 45 degree copper street elbows. I then got my tools out and gathered up supplies I needed to disconnect the fan-coil heat exchangers and heater hoses.

I started by trying to connect a 1/2″ i.d. clear vinyl tube to the drain stub on the Aqua-Hot. The stub points straight down, is approximately 3/4″ long, and the open end is about 3/4″ above the base. There is a hole in the base of the unit at that point, provided by Aqua-Hot for a drain line, but Royale Coach installed one of the CruiseAir condenser units directly beneath the Aqua-Hot and did bother to provide a hole in the shelf or make alternate arrangements for draining the unit. I could not get the vinyl tube over the stub and with a limited amount of time to spend on this minor annoyance moved to Plan B.

We have had a large stainless steel photo processing tray, approximately 2′ X 3′, for years. Today we used it to catch antifreeze and protect the new floor. Linda got some scrap towels and we put them under all of the edges of the tray. I then set the heat exchangers on pieces of 2×4 in the tray to keep them up out of the antifreeze. Linda held the heater hoses as I undid each of the band clamps in turn and worked them loose from the exchangers. We emptied the coolant from the exchangers and hoses into the tray, wiped off the heat exchangers, took them outside, and set them in the driveway.

The two fan-coil heat exchangers in the photo tray ready to have the coolant hoses disconnected.

We made sure the hose that connected the two units was drained, wiped it off, and took it outside. This hose has bleeder valves at each end that I will have to remove as I need to reuse one of them. We drained the two remaining hoses as best we could and put the open ends in the metal photo tray. I bought a bucket yesterday with a gasketed lid that has a built in spout. I picked the band clamps and pieces of 2x4out of the antifreeze and put them in the bucket. We then carefully poured the antifreeze from the tray into the bucket and put the lid on. We carried the tray outside and set it in the driveway and then took the bucket outside.

Linda took a break from stripping wallpaper and went to the bank to deposit proceeds from the recent rally. There wasn’t anything else I could do in the coach and I turned my attention to cleaning up the work surface in the garage. I took the two desk bases to the garage and started working on the installation of the grates and heat exchangers. I had not worked through the details of this in advance so I had to figure them out now. I started with the left base, which has an angled front.

The coolant hoses with the heat exchangers removed. We were able to contain the coolant in the tray and not get any on the new floor tiles.

The heat exchangers needed to be spaced up 1/2″ off the floor to better align with the openings in the sides so I cut pieces of 1/2″ plywood to put under them. The exchangers have two holes on the bottom front edge that were probably created by Royale to mount them. Actually, it appears that Royale mounted them upside down, presumably to position the coolant connections where they needed them. I say they were upside down because I discovered labels on the “bottom” indicating they were made by “Vantage Products, Exclusive U. S. Distributor of Primus Hydronic Heating Products.” I designed the desk bases so that the exchangers would mount the same way Royale had them. As such they will remain “upside down” but it will not affect their operation.

My plan was to put 3/8″ wide by 1/4″ thick dense foam self-stick weather stripping around the edge of the discharge side of the exchangers to seal them to the base and reduce vibration noise due to the fans. I cut the 1/2″ plywood large enough to provide room for mounting brackets to attach the plywood inserts to the base in locations that I could reach with the heat exchangers in place. The exchangers had to be screwed to the plywood before it was set in place inside the base since the grates blocked access to the two mounting holes.

The two fan-coil heat exchangers that will go in the bases under the two desk pedestals.

By now it was mid-afternoon Keith showed up and mowed the grass so I took a little time out from my work to chat with him. When I returned to the makeshift workshop in our garage I cut the brass-colored decorative aluminum grates to size and secured them on the inside of the base using small screws. I also wanted to add a layer of the plastic gutter mesh I bought yesterday. After cutting the first piece to size I decided to use double stick tape. The only tape I had was 3M Extreme Duty Mounting Tape so I drove to Lowe’s to get something more appropriate. I found a 1″ wide clear tape and decided to try it.

Half inch wide tape would have been better so I tried cutting the 1″ tape in half lengthwise. I removed the discharge grate, applied the tape to the edges on the back side, and pressed the plastic mesh into it being careful to keep it as straight as possible. I then screwed the whole assembly on the inside of the base. The screws did not like going through the tape or the mesh so I was quickly disabused of this assembly process and decided to use the tape as it came off the roll.

For the air intake grate I first screwed the metal sheet to the inside of the base. I then applied shorter pieces of tape around the edges in-between the screw heads. I carefully positioned the pre-cut plastic mesh, peeled the protective layer off of the tape, and stretched/pressed the mesh in place.

I needed to clean the 3/4″ copper inlet and outlet pipes on the heat exchanger so I got Linda to help me at this point. She held the heat exchanger as I used a strip of plumber’s sandpaper to remove heater hose rubber that had stuck to the pipe.

Because of the grates on the air openings in the base I positioned the plywood spacer and then marked/drilled the holes for the mounting brackets. I set the exchanger in place, made several alignment marks, removed the exchanger, and took out the plywood. I attached the brackets to the inside of the base and then attached the weather stripping to the front of the exchanger case. I positioned the case and Linda held it while I secured it with two screws. I slipped the plywood/exchanger assembly back into the bottom of the base and Linda pulled it tight to the front while I secured the brackets to it. One base done, one base to go.

Keith was done mowing about this time and stopped to see what we were up to and pick up his check. He normally mows our property on Monday morning but had some service issues with his truck that put him back a day. He had some string trimming to finish and our dinner was ready so he went back to work and we went inside to eat. Dinner was salad and Whole Wheat ABC Pasta Veggie Soup. The soup was a North Bay Trading Company mix that Linda got at Whole Foods. She added kale and tomatoes to make a very tasty and nutritious dish.

After dinner I was closing up the bus for the evening and noticed that the two large MCD shades in the living room had come loose from their front mounting brackets. This undoubtedly happened Sunday on Hacker Road as we returned from the rally in Elkhart, Indiana. Linda helped me move one of the desk pedestals on the sofa so I could get to the shade on the driver’s side of the coach. Once I could get to it the mounting rail snapped into the clip fairly easily but I will have to figure out why it popped out in the first place and make adjustments if needed/possible.

I checked e-mail and replied at length to one from Gary at BCM. We then settled in to watch the season opener of NCIS and NCIS New Orleans (NCISNOLA) followed by several shows on CreateTV (PBS). I multi-tasked, working on blog posts at the same time.

My work yesterday and today was not as physical as what we have been doing for most of the summer so it did not feel like I had done much but the evidence suggested otherwise. These seemingly small tasks often have a lot of steps that have to be done carefully in the right order and take time to do. There was also a certain amount real-time problem-solving and a trip to the store in the middle of the work. I hope to finish the other base tomorrow, get both of them back in the coach, and get them plumbed with the new heater hose. That may have to wait a day or so, however, as Linda needs to finish stripping the wallpaper in the area behind the desk and we need to hang the new paper before re-installing the desk. There is a definite order to this work that cannot be circumvented.

The Phase Place

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Tag Archives: desk base heat exchanges (H3-40)

2015/10/13 (T) Desk Alignment

2015/10/11 (N) Now Heat This

2015/10/08 (R) A Mighty Hose

2015/10/07 (W) The Root Cause

2015/09/23 (W) Autumnal Equinox

2015/09/22 (T) Bench Work