Tag Archives: entry-cockpit-landing (H3-40)

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.

 

2015/09/26 (S) A Step in the Right Direction

We missed our ham radio club breakfast last week because we were at an RV rally and we plan to be at another rally three weekends from now so in spite of all the work we still have to do on the bus we went to breakfast in South Lyon.  After breakfast we went to the Lowe’s in New Hudson, which is close to South Lyon, and bought a Porter-Cable 1/4 sheet palm sander.  The sander is small enough to get into corners but has an integral dust collection bag.  The bag can be removed for sanding in really tight spots, but it cuts down on airborne dust while sanding and reduces the amount of cleanup afterwards.  We have several other Porter-Cable power tools and I am generally pleased with them.

Back at the house we took care of a few chores and then got to work on the bus.  Linda continued working on stripping the old wallpaper behind the sofa while I pondered for a while about what to do before deciding to concentrate on rebuilding the landing at the top of the entry stairs.  This landing is where the pneumatic entry stairwell slide cover was installed.  Without all of that “stuff” in place the last step up to the landing was now too short and the step up to the copilot level was too tall.  More importantly, the step heights were all different, and would be a built in trip hazard if not corrected.

I determined that the 2.5″ wide poplar boards installed on edge with a 3/4″ thick plywood floor and a top layer of 3/16″ SurePly underlayment would match the top surface of the plywood in the driver’s area.  That would (should), in turn, allow me to install the new vinyl floor tiles so they bridge that seam.  I will have to reuse the plywood in the driver’s area, but worst case that will require using adhesive remover followed by floor patching compound and sanding before installing the tiles.

The landing was not “square” (of course) so I made and rechecked measurements several times.  I then built a four-sided frame that fit snugly and had the front board aligned with the face of the plastic riser.  I am going to tile the steps and I am not going to use underlayment so I needed these surfaces as aligned and flat as possible.  I will probably use floor patching compound, however, to fill the gaps before installing the tile.  I used screws to secure the frame to the adjacent vertical wood that forms the riser to the copilot level and to the base of the landing with angle brackets.

I needed a piece of 3/4″ plywood approximately 31-1/8″ x 27-5/8″ for the new landing as the old piece I took out was not in good shape and I did not want to reuse it.  I did not have any other 3/4″ plywood pieces that were large enough so I went to Lowe’s.  They did not have 3/4″ half sheets (4′ x 4′) but I bought some more angle brackets while I was there.  I then went to The Home Depot.  They also did not have 3/4″ half sheets, but they had full sheets of 23/32″ sanded plywood that looked like it would work and a nice panel saw with an employee available to operate it.  I waited while he built a complete set of closet shelving for a couple and engaged in some domestic counseling.  He then cut the plywood sheet into two 4′ x 4′ pieces and helped me load them into a cart.  I was able to get them into my Honda Element by myself and close the back hatches.  I had a nice QSO with Steve (N8AR) on the drive home via the South Lyon 2m amateur radio repeater.

Linda had long since finished working on the wallpaper and busied herself in the kitchen preparing collard greens Cole slaw and vegan potato salad.  It was somewhere between late afternoon and early evening but I still had enough light to work outside.  Linda was still busy cooking so I decided to go ahead and try to cut the plywood for the new landing.  Again, it was not a rectangle, i.e., an equiangular quadrilateral (four right angles and four sides with opposing sides parallel and equal in length) so getting the shape exactly right was tricky.

I determined that the right front corner, as viewed from the entry steps, was a right angle, or close enough to one to provide a known starting point.  I put the plywood on 2″x4″s on the flat in the driveway to elevate them so I could clamp a saw guide in place and provide clearance for the saw blade.  I measured the lengths of all four edges as best I could and placed the right front corner at a factory corner of one of the 4′ x 4′ pieces.  I marked the length of the right side and the front on the two factory edges.  The left side was longer than the right side and the rear side was longer than the front side so I marked arcs for the left and rear lengths and found their point of intersection.  If the right front corner was, in fact, a right angle them this had to result in the correct shape.  The key word in that last sentence is “if.”

I tried to confirm my layout by measuring the lengths of the diagonals on the plywood and on the bus but I could not get accurate measurements in the bus.  I triple-checked my measurements and layout then marked the guide lines for the setback on my circular saw; 6-5/8″ to the inside edge of the teeth on the blade.  Truth be told I initially marked the guide lines on the wrong side of the cut.  I started to adjust my guide board to the outside of the blade and then thought better of the idea.  The guide needed to be set up so that if the blade wandered off course it would cut into waste material rather than the finished piece.  I re-measured and marked the guide lines in the proper place, checked their location with my small square, checked with the saw, made minor adjustments, and finally made the first of two cuts.  I then repeated all of that and made the second cut.  When I set the piece in place in the bus it was a perfect fit.  I was so pleased that I had Linda come out to see it.  Sometimes I amaze even myself.

I like to quit on a high note so that was the end of our bus work for today.  We did not make dramatic progress but we kept moving and got things done that needed doing.  My work today involved a certain amount of pondering and on-the-fly engineering combined with careful, repeated measuring and accurate cutting.  This kind of work is never fast.

A beautiful sunset had developed, which meant it was getting dark, so I put a few things away and closed up the bus while Linda prepared our dinner.  She made a nice salad and heated a couple of Amy’s vegan (non-dairy) lasagna entrées.  A glass of Moscato was a welcome accompaniment and we enjoyed a second glass as we relaxed in the living room.  We got a Rockler catalog in the mail today so I looked through that.  If you are into woodworking it’s the adult equivalent of the Sear’s Christmas catalogs of yesteryear.

I called Butch at 10 PM.  It was 7 PM in Bouse, Arizona and I figured they would be done working for the day and probably already had their dinner.  The daytime highs there have been reaching 110 degrees F so Butch and the other RV Park employees have been starting work between 6 and 7 AM and trying to finish up by 1 PM.  He did not elaborate but said the situation the first two weeks has not been exactly what they signed up for.  He had already responded to an e-mail from Linda with more details so we let it go at that and talked about other things.  We wrapped up our conversation at 10:30 and I went to bed.  I was going to play a couple of games and then go to sleep but there was an update available for the iPad OS so I installed it.  9.0.1 was a big update and took quite a while to install.  I was very sleepy by the time it finished and turned out the lights.

 

2015/09/25 (F) Miss Dig

I turned the lights out at 11 PM last night and slept until 8:15 AM this morning.  I was preparing coffee when Linda told me there were wild turkeys in the back yard.  They were gathered at the deer feed block and more showed up while we were watching.  There were 15 in all, and they were big.  We had our usual granola for breakfast with fresh blueberries, strawberries, and bananas.  We finished our morning routine and coffee at 10 AM and got back to work on the bus.

Linda continued working on removing the old wallpaper while I worked on the entry and cockpit.  She used a drywall sanding sponge to try and remove the last little bit of material from the walls she stripped yesterday and it worked rather well but not 100%.  I was able to remove the step well cover assembly yesterday and today I removed the last step before reaching the main floor.  It did not come out easily; the three screws securing it to two adjacent walls were badly rusted and the Philips heads would not hold the screwdriver bit.  I ended up prying them loose, and inelegant (brute force) but effective solution.  I am going to rebuild this step with a slightly deeper run and an open front so we can store shoes under it.  First, however, I have to tile the floor.

I spent some time examining the old tile in the driver’s part of the cockpit.  It clearly goes under the accelerator pedal but around the brake pedal.  That’s reasonable as the accelerator is electrical, with only a cable that goes through a small hole in the floor, while the brake is pneumatic and the major part of it is in the bay below the floor with all of the air lines connected to it.  I came to the conclusion that the tile was also installed under the seat base, which means Creative Mobile Interiors removed the base to install the tile.  I did not come to a final decision regarding removing the tile versus tiling over it, but I am leaning towards removing it.

I was also able to determine that the retaining nut on the swivel bases for the pilot and copilot seats was 15/16″ and accessible from the rear with the seats moved forward.  That means I can remove the seat, 6-way power base, and swivel plate as one assembly by removing one nut.  I will then have excellent access to the pedestal mounting bolts and the driver’s area once everything else is out of the way.

Rebecca from Shutz HVAC called at 10:30 AM and arrived about 15 minutes later.  Shutz is the HVAC installation contractor for the Lowe’s in Howell and she was here to look at our main air-conditioning system and give us a quote on a new Trane system as that is what Lowe’s sells.  Lowe’s had a Pro Show on Wednesday and Rebecca was staffing the Shutz table so we stopped to chat.  She let us know that everything at Lowe’s was on sale through tomorrow at closing for 10% off with our Lowe’s credit card, including installation labor.  The card is automatically good for 5% off on any product purchase so the extra 5% is not enough of an incentive to cause us to make the purchase, but we were curious what a new system might cost.  I will get a quote from Darryl at DCM, however, before making any decisions.  Also, our friend Mike (W8XH) recently had an A-C system installed and was very happy with the company, product, and installation so I will find out who he used and get a quote from them too.

Rebecca was very nice and very knowledgable.  After looking at the condenser/compressor outside I got a step ladder and she went up in the attic to look at the old air-handler/evaporator.  The system is a Coleman and we have no idea how old it is; we just know that it did not do a good job of cooling the house this summer.  The quote was for a “3 ton” system for $7,800.  With 10% off it came to $7,020 but that price was based on flushing, testing, and reusing the existing refrigerant lines, which did not sound like a good idea to me.

Charles from USIC (Miss Dig) showed up around 11:30 AM to mark the utilities.  Phil plans to start digging and grading next week, hopefully Tuesday.  Charles came to the front door and I excused myself from the air-conditioning conversation to walk the property with him.  I explained what we were having done and showed him where the work would take place.  He marked the main gas line along the entire length of our property, a portion of the branch line going to our meter, the tie in for the branch line to the house across the street, and the T at the northwest corner of our property where the main line splits to service the court.  He also marked the phone line, which runs underground from a pole west of our house to the southwest corner of our garage.  The main electrical service runs underground with the phone line but someone else has to come out and mark that.  I chatted with Charles briefly before he left and then called Phil and left him a message.

Last summer Darryl from DCM Heating and Cooling installed a new natural gas furnace with an air conditioner for our library, a natural gas heater in our garage, ran all of the black iron pipe, including 160 feet of 2″ line, hooked us up to the gas meter, and got everything working for just under $11,000.  The Trane system would be bigger than the one for the library, and the air-handler in the attic is a more difficult installation, but $7,800 for just the air-conditioner without new refrigerant lines seemed a bit high.  After Rebecca left I called and left a message for Darryl.

Linda was ready to strip the wallpaper behind the built-in sofa so we moved the two desk pedestals onto a blanket on the kitchen floor in the bus and unscrewed the seat and set it on top of the desk pedestals.  When I finally got back to work on the bus I removed the cover for the front OTR HVAC system and set it aside.  I was trying to get access to the underside of the wood trim that includes a grab handle that needs to be tightened but had a look around first.

I noticed a damper controlled by a flexible cable and figured it was what determined if the air was fresh or recirculated.  I turned the knob on the dashboard and saw the cable move but not the damper.  The damper was stuck so I loosened it by hand but the knob still did not cause it to move.  I then noticed that the sheath of the flexible cable had come loose from its retaining clip.  It was a tight spot in which to work but I was able to loosen the two screws holding the clip using a right angle screwdriver.  I slipped the sheath under the clip, tightened the screws enough to hold it, and turned the knob.  It worked!  On a day when I did not feel like I was accomplishing very much this was a tangible and unexpected success.

I removed the only four visible screws from the wood trim but it would not budge.  I had tried removing it once before without success but was determined to get it loose this time.  The only reasonable explanation was that CMI had glued it on after tightening the grab handle as part of the initial work we had them do right after we bought the coach.  I carefully worked a pry bar under the passenger side end and gradually applied force to it.  It was, indeed, “glued” on but it appeared that I would be able to pry it loose without breaking anything if I took my time.

When I did finally get it off I could see that they had used clear silicon (adhesive) caulk to attach it to a dark gray plastic piece.  Royale Coach had originally attached it to this plastic piece using four screws.  The plastic piece turned out to be the lower windshield defroster duct and I am considering how we might finish this without replacing the wood trim.  Wallpaper is currently at the top of my list but I doubt that it would be a good solution.  Of further interest to us was the wood itself.  We presumed it was maple based on the color but were puzzled why they would have used a different wood in the entryway.  Once we saw the back side, however, it was obviously walnut that lightened where it was exposed to light to the point of looking like maple.  There is other wood in the entry and copilot area that is equally light and we now realized that we had a refinishing task and not just a cleaning task, ahead of us at some point.

My next task was to scrape as much of the caulk off as I could.  I got a lot of it off, but not all.  Silicon caulk is difficult to remove.  I eventually found a single edge razor blade holder and blade and used that to get the last bit off.  I then worked on removing layers of masking tape from the edges of the base where the former step well slide was installed.

I have some carpentry to do to rebuild the steps and prep them for the tile installation and needed some materials and supplies so I went to Lowe’s and got:

  • Adhesive remover;
  • A 4’x8′ sheet of 3/16″ SurePly underlayment;
  • Two 3/4″ x 2.5″ – 6′ poplar boards;
  • A 15/16″ open or closed end ratcheting wrench;
  • A bottle of Piranha Wallpaper remover;
  • A Piranha wallpaper remover sponge;
  • A pack of 2,000 18 gauge 3/4″ long x 1/4″ crown staples;
  • A pack of 25 sheets of 120 grit and a pack of 25 sheets of 220 grit 1/4 sheet sandpaper.

I got 10% off the total bill! which was nice.  I did not get a palm sander as they were out of the Porter Cable model I wanted.  The Lowe’s in New Hudson showed two in their inventory so we will stop there tomorrow after breakfast and get one.  I also needed a half sheet of 3/4″ plywood to make a new platform to replace the step well slide but did not feel like dealing with that.

For dinner Linda heated some butternut squash ravioli she bought at Whole Foods.  She served it with sliced vegan Italian sausage cooked with mushrooms, onions, and garlic, a side dish of steamed fresh green beans, and a glass of Moscato.

After dinner I uploaded my blog posts for July 23 through 31 plus a gallery post of 11 photos I got from Jarel Beatty of the custom walnut desk in the process of being built in his shop.  I got a call back from Darryl and we discussed the new air-conditioning system.  He said he would get me a price but advised us not to let anyone reuse the old refrigerant lines.  If they are not 100% clean the old refrigerant will contaminate the new system.  If Shutz installs the Trane system it comes with a 10 year parts and labor warranty, but it would still be a hassle to deal with getting a contaminated unit repaired or replaced.

After chatting with Darryl for a while we agreed that there wasn’t any urgency to this.  For one, we need to have Darryl check the current system for leaks, and assuming it does not have one, for proper refrigerant charge, cooling capacity, and airflow.  Darryl is busy doing heating systems at the moment, but is willing to do the maintenance work.  Also, the cooling season is done for this year and we will be traveling during the hottest part of next summer.  A final factor is that this has been another expensive summer for us with the new roof on the house, the interior remodeling of our motorcoach, and the work Phil is about to do, so we would prefer to defer this expense.