Tag Archives: fan-coil heat exchangers

2015/10/08 (R) A Mighty Hose

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.

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.

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.

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.

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.

 

2015/06/16 (T) More Stupid

Linda was scheduled to go to the bakery this morning but rescheduled to tomorrow due to last night’s weather forecast and the possibility of flooded highways in Detroit.  The morning rush hour traffic is bad under the best of conditions and flooded roadways can make it near impossible.  She also did not sleep well and woke up tired.

The Apex roofing crew started showing up just before 8 AM and the Wimsatt truck showed up with the shingles a little after 8 AM.  They brought a conveyor truck this time and were able to get the shingles off the truck and onto the roof without difficulty.  The Apex crew did not waste any time getting to work.  It turned out to be a great day for roofing; clear skies, no rain, moderate temperatures, lower humidity, and some breeze.  Even so, it is work that is done without the benefit of shade and roofs are hot places to work even on the nicest of days.

Wimsatt unloads shingles onto the garage roof.

Wimsatt unloads shingles onto the garage roof.

Linda continued working on the financials for our amateur radio club while I checked my e-mail.  I had a reply from RV Critter Guard telling me what to order and how much it would cost.  I placed the order through their website and used PayPal to complete the transaction.  I tried calling the concrete contractor that Phil recommended (Bid Rite Concrete LLC in Whitmore Lake) but the phone would disconnect after the first ring and revert to a dial tone.  Perhaps the recent storms caused a problem but I e-mailed Phil to see if he had a different number for them.  I called the Henry Ford Medical Center in West Bloomfield and made dermatology appointments for myself and Linda.

With all of that taken care of I turned my attention to the bus.  The toilet is a Microphor LF-210.  It uses pressurized air to operate the waste valve and the water valve and to help push the waste through the drain pipe and into the black tank.  To remove the toilet I had to undo three connections—air, water, and waste—and take out the four screws securing it to the floor.  If only it was as easy as that makes it sound.

The plumbing at the back of the Microphor toilet in our bus.

The plumbing at the back of the Microphor toilet in our bus.

Undoing the air line was easy and undoing the water connection only a little less so.  The waste connection was another matter.  The 1.5″ black plastic drain pipe was routed from the water bay through the floor and into the HVAC chase that runs along the driver’s side of the coach.  The converter, Royale Coach, brought it out through a hole in the wood that covers the chase, making it impossible to take the wood cover off.  The pipe then made two right angle bends, the first one towards the floor and the second one towards the back of the toilet.  The waste pipe was connected to the toilet discharge pipe with a length of rubber hose and a compression sleeve.

The toilet has a large hole in the back for all of these lines to pass through to the inside where they get hooked up.  It should have been a simple matter to slide the toilet away from the wall/chase but the last bend in the drain line was below the top edge of the bottom of the hole, preventing it from coming out.  After wiggling the toilet enough to get the rubber hose loose from the drain pipe I was able to lift the drain pipe just enough to slide the toilet out.  I took pictures for a possible BCM article on our interior remodeling project and then Linda helped me move the toilet out of the bathroom to the front of the coach.

The more I disassemble this coach the more stupid I think the design and construction of its systems are.  I don’t know that coaches from Marathon, Liberty, Vantare, Featherlight, Parliament, Millennium, Custom Coach, or any of a dozen other companies that have come and gone, is any better as I have never tried to disassemble one of them.  These are one-of-kind vehicles that are custom built specifically for the original purchaser and the over-riding factor in every case is the interior design.  Stuff, like toilets, go where the customer wants it, and systems, which are generally buried and hidden from view, get built wherever and however they can be made to fit.  The converter does not expect to have to repair or replace anything during the very short 12 month, 12,000 miles, warranty period and if stuff breaks after that, or someone wants to do a remodel or upgrade sometime later, it will all be time and material.  How difficult it is to do, and how many hours it takes, is someone else’s problem at that point.

The Apex crew hard at work on the back side of the main roof.

The Apex crew hard at work on the back side of the main roof.

We had a call from Butch updating us on a possible property purchase.  They are waiting for a clear title search before making an offer.  The property includes a house and a sizable barn.  The barn needs a new roof and the house will have to be gutted and the inside rebuilt, but for the right price it will still be a good deal.  They already have a good estimate to replace the barn roof and since they are now retired they have more time to work on the house than they would have a year ago.  They also have family and friends who can help.  Besides, they still have their home/business building in Twelve Mile, Indiana and their bus, which they lived in all this past winter, so they will not be under any pressure to get the inside rebuilt quickly.

Linda started downloading updates from Adobe Creative Cloud, which take a very long time, and then left at 3:30 PM for Ann Arbor.  She agreed to take care of grand-daughter Madeline while Brendan and Shawna attended a reception at the University of Michigan – Ann Arbor for newly tenured and promoted faculty.  I was on my own for dinner and Linda bought an Amy’s pizza so I would have something easy to prepare.

The roofers finished up for the day around 5 PM.  By the time they left most of the trash was in their dumpster trailer and the roof was tarped as a precaution against rain even though the forecast for tonight and tomorrow is for dry weather.  Rain returns to the forecast tomorrow night into Thursday but turns dry again on Friday, so we are optimistic that they will get the job finished this week.  It’s a big job but Apex has a big crew working on it and they got a lot of work done today.  We are very pleased with the look of the Certainteed Landmark Pro Max Def Resawn Shake shingle that we chose.  I took pictures of the work throughout the day as I always try to do with major projects.

After the roofers left I worked for a while in the bus.  I took the mattress into the house along with the electric heating pad controls.  I disconnected the two gas struts that support the plywood bed platform so I could open it far enough to reinstall one of the drawers.  I left them disconnected as I plan to remove the platform to provide better access to the sides of the box and floor.  I also plan to reposition them when I reinstall the platform to provide better access to the storage area underneath.  I then took measurements and made a sketch of the file drawer box for the desk.

Installing soffit baffles and replacing roof decking on the front of the main roof.

Installing soffit baffles and replacing roof decking on the front of the main roof.

I cooked the Amy’s Roasted Vegetable Pizza on the outdoor gas grill, both to avoid heating up the house and to see how it responded to that cooking method.  I used the grilling mat and the result was quite acceptable.  A glass of Franzia Moscato was a nice accompaniment.

After dinner I worked at the drafting board in my office turning my sketch and measurements into a scale drawing.  The two boxes for the desk will be trickier than a standard desk box because of the HVAC chase and because I have to put an Aqua-Hot heat exchanger in the bottom of each one.  I worked until about 9 PM and then came back upstairs.

The air-conditioner worked fine yesterday but was once again unable to bring the temperature in the house below 74 degrees F even though the outside air temperature never rose above 80.  There is clearly something wrong and I am wondering if one of the cold air ducts is open into the attic and/or one of the return air ducts us drawing hot air from the attic.  Either of these conditions would reduce the air flow to the house and overtax the evaporator in the air handling unit.  The more likely cause, however, is lack of refrigerant.  Whatever the case I shut the system off and opened up the house.

I was relaxing in the living room when Linda called at 9:30 PM to let me know she had left her babysitting gig and was stopping at the Whole Foods Market before heading home.  The reception started at 5 PM and lasted until 9 PM.  She was home by 10:15 PM and straight away to bed as she has to go into the bakery tomorrow and wants to leave early enough to be ahead of the morning rush hour traffic.

 

2014/10/23-29 The Bus Work Continues

2014/10/23 (R) Close Encounter of the 1st Kind

My two main bus projects today were the lighted handle by the entrance door and the Progressive Industries remote display installation.  The lighted handle needed new machine screws and some additional gasketing on the upper securement.  It turned out that all five of the screws that I removed were stripped to a greater or lesser extent.  After trying several different screws I concluded that the threaded holes must be messed up.  Butch loaned me a 10-24 tap and I used it to re-tap all five of the mounting holes.  I cut two additional pieces of the vinyl shower pan liner and trimmed them to fit just inside the upper securement.  That allowed the piece to be reattached to the body using the 10-24 stainless steel screws I bought last night without causing interference with the LED bulb.

Some time ago I bought a remote display kit for our Progressive Industries Energy Management System (EMS).  The kit consists of a second display unit and a selector switch unit.  I mounted the selector switch in the utility bay in place of the display unit, moved the display unit to the left, and connected it to the switch with the short cable provided in the kit.  I routed the long cable from the switch through the bay to the other side by the Aqua-Hot and fed it through a small hole into the electrical bay, which is the next bay going towards the front of the coach.  I temporarily mounted the remote display in the house panel.  I then repeated the work I had done yesterday to relocate the Magnum inverter/charger remote.  This time I used serial cable #1, removed the DB-9 connectors from each end, and connected the wires on each end.  The difference from yesterday is that Progressive Industries wires their cables so that pin 1 of the RJ-11 on one end is wired to pin 1 of the RJ-11 on the other end.  That meant I had to keep the wire colors the same between the two surface-mount phone jacks, i.e., black-to-black, red-to-red, green-to-green, and yellow-to-yellow, rather than cross wiring them like I did yesterday.

ITR Oasis Combi in Butch & Fonda's MC-9.

ITR Oasis Combi in Butch & Fonda’s MC-9.

Butch’s major focus today was the ITR Oasis Combi.  He and Fonda worked for much of the day running new diesel fuel lines.  By late afternoon I was done with my projects and went to work on the fresh water plumbing for the Oasis.  Prior to the last couple of weeks I had not worked with PEX tubing and fittings.  Butch has a crimper that he showed me how to use.  By the time we quit working to have dinner we had the fresh water tank connected to the inlet of the Shur-Flo 4048 pump, the outlet of the pump connected to T-fitting that supplies cold water to the house and to the Oasis Combi inlet, and the outlet of the Combi connected to the line that supplies hot water to the house.

For dinner I fixed a salad, a Thai Kitchen mushroom noodle soup bowl, and a bowl of fresh strawberries for dessert.  I took everything in the house and dined with Butch and Fonda.  After dinner I went back to the coach to try and straighten things up a bit.  I must have opened the cabinet door under the kitchen sink a dozen times to throw away food scraps, product packaging, and paper towels.  I had bundled up the various recyclables and opened the cabinet to remove the trash bag when the mouse jumped out and ran under the passenger side couch.

I say THE mouse because I presume it is the mouse that has obviously been in the coach recently based first on getting into my loaf of bread and then finding a nest where none had been previously.  It was a cute little dark gray field mouse, not more than two inches long (without its tail), but I am going to have to find a way to catch it and remove it.  I will set a live (no kill) trap next week and see if I can find it a nice field to live in somewhere far away from Butch and Fonda’s house and both of our buses.

It was still in the upper 40s and rather pleasant outside so I straightened up the back of my car rather than wait until morning.  After retiring to the guest bedroom I organized most of my clothes.  I should be packed and on the road about an hour after I get out of bed in the morning.

2014/10/24 (F) Around the World in 80 Days

As much as I have been traveling back and forth between Michigan and Indiana I feel as if I could circumnavigate the world in 80 days but today my “journey of a thousand miles” began with a 260 mile trip home.  I was up a little before 8 AM and finished packing all of my stuff in the guest bedroom and loading it into the car.  I gathered up some last minute laundry, foodstuffs, and recyclables and put those in the car as well.  I sat and chatted with Butch and Fonda until 9:10 AM and then said farewell until Sunday evening.  I pulled my car out its normal parking spot at 9:15 AM and headed east on SR-16.  I followed my usual route home from there: US-31 north to US-20 east to CR-17 north to I-80/90 (Indiana Tollroad) east to I-69 north to I-96 east to M-59 east to Hacker Road south and then home.

Hand cut gaskets for upper piece of lighted entrance handle on our coach.

Hand cut gaskets for upper piece of lighted entrance handle on our coach.

Our friend Kate had contacted us yesterday to see if we were available to go to the Meadow Brook Theater to see a live theatrical performance of an adaption of Jules Vern’s Around the World in Eighty Days.  Her cousin is working as an intern at the theater this season and was able to get courtesy tickets.  Linda was feeling well enough to go so we left early and stopped at a Panera on the way over to the theater where we met up with Kate.  The performance was very good and we thoroughly enjoyed it.  We wanted to have coffee together afterwards, but by the time we met her cousin and chatted for a while it was late and everything was closed.  Besides, we had an hour’s drive to get home and Kate probably had at least 90 minutes.

2014/10/25 (S) Here And There

Linda slept in to rest and try to recover from her cold so I went to the SLAARC Ham Radio Club Breakfast by myself.  She was awake by the time I got back and feeling well enough to run errands with me.  We stopped at Recycle Livingston and then picked up our new natural gas fireplace logs from Country Squire in Howell.  We got the business card of the independent technician who does installations for them and gave them a call to set up an appointment.  I left a message and they called us back later.  We stopped at our Bank of America branch enroute to Staples in Brighton in search of a larger size of graph paper, but they did not have the size I wanted.  I need larger paper to draw accurate designs for the custom desk/pantry and printer stand/table that we want to have made for our converted bus.  We fueled up at the Brighton Meijer’s and then bought groceries.  We needed a new coffee maker but decided not to purchase one until we had checked online.

Back home we searched for coffee makers in a white finish rather than black/stainless.  There were only a few choices and one of them was a Mr. Coffee programmable model that was available at Bed, Bath, and Beyond.  As long as we were looking for things online we found a pad of 50 sheets of 17″x22″ graph paper with a 1/4″ grid pattern and added that to our Amazon Prime shopping cart.  We also added a Camco RhinoFLEX RV sewer hose kit and various accessories.

Back side of house systems panel.  Bus conversions are complex.

Back side of house systems panel. Bus conversions are complex.

Linda had arranged for us to meet John and Diane at Camellia’s in Farmington Hills for dinner at 6 PM.  We left the house around 4 PM and stopped at the Brighton Bed, Bath, and Beyond to get the Mr. Coffee coffee maker.  We stopped at the Meijer’s in Wixom and picked up the filters and then stopped at J. C. Penney’s at Twelve Oaks Mall for some necessary clothing items.  We headed into Farmington Hills but were still early for dinner so we drove through our old neighborhood, which is very close to the restaurant.  Our former across-the-street neighbor, Dan, was working on a car in his driveway so we stopped to chat.  While we were there the young man who bought our house arrived home on his motorcycle.  He never removed his helmet before putting the bike in the garage and shutting the door, so we never actually saw him.  Our daughter handled the closing in July 2013 since we were in Wyoming at the time, so we never meet the buyer or his parents.  He has apparently been a very quiet neighbor who keeps to himself.

We got to the restaurant shortly after 6 PM and John and Diane were already seated so we did not have to wait for a table.  We had the veggie fajitas, our standard choice at this particular Mexican restaurant.  While we were dining our friends, Jim and Kristine Gullen, came in and sat in a booth near us.  When we were done with dinner John and Diane headed to their house (nearby) and we lingered for a few minutes to chat with Jim and Kristine before joining them.  Diane had bought some Coconut Bliss Chocolate with Salted Caramel non-dairy “ice cream.”  It was the best vegan ice cream we have had.  By 10 PM we were all having trouble staying awake so we said farewell and headed for home and went quickly to bed.

2014/10/26 (N) Pack and Go

We both slept in this morning, the combined effect of being tired (both of us), sick (Linda), and having taken Tylenol PM last night (both of us, again).  In spite of her cold, Linda wanted to cook something for me before I took off again for Indiana, so she made her wonderful vegan blueberry pancakes for breakfast.  We used the new coffee maker and, as expected, the coffee tasted the same as with the old one.

After breakfast we sorted and folded laundry (we have such exciting lives) and I selected and packed the items I needed for the week ahead.  I had not copied photos from my laptop to the network drives since October 10th so I took care of that.  I also made more careful measurements of the dimensions of our color laser printer to use in refining the design of the printer cabinet for the bus.  Likewise, I took measurements of our Dewalt air compressor as I plan to build a wooden divider for the back of the Honda Element that will secure it on the floor and create space next to it and above it for storing other things.  Obviously the two rear seats will be removed when this insert is in use.

Junction boxes for the ME-ARC remote (bottom) and the PI-EMS-50 (top)in the house systems panel.

Junction boxes for the ME-ARC remote (bottom) and the PI-EMS-50 (top)in the house systems panel.

By 2 PM I was ready to load the car so Linda helped me with that task.  I pulled out of the driveway at 2:16 PM and followed my usual route to Indiana: Hacker Road north to M-59 west to I-96 west to Lansing Road south to I-69 south to I-80/90 (Indiana Tollroad) to CR-17 south to US-20 west to US-31 south.  I exited US-31 at IN-25 (Rochester), topped off my fuel tank and then picked up fresh greens and fruit at the Kroger.  I headed south on IN-25 to Fulton where I took Aitken Road east to Meridian then headed south to SR-16 and finally headed east to Twelve Mile.

Butch and Fonda had their family holiday gathering today.  They had 27 family members in attendance during the day and for dinner but by the time I arrived (7:45 PM) everyone had left except Brittiny and Rock, and they departed while I was unpacking food and storing it in the coach.  I moved all of my clothes and technology into the guest bedroom, like I always do, and then visited with Butch and Fonda for a while before retiring to my room for the evening.  If the weather forecast holds true we have two unseasonably nice days in store on Monday and Tuesday and the rest of the week doesn’t look too bad either. We have a lot to do and could use some favorable weather.

2014/10/27 (M) Heat and Light

We had an unseasonably nice day for working outside.  It was already in the upper 40s when we got up and made it in to the 70s under partly cloudy skies with breezes from the southwest.  I was up before 8 AM and had my usual granola, orange juice, and coffee for breakfast and then got to work.

Butch worked most of the day on assembling the two fan-coil heat exchanger units that will get plumbed into their ITR Oasis Combi diesel-fired hydronic furnace to provide heat to the house portion of their converted bus.  While he worked on that I worked on replacing our patio light.  The ballast on the old one was no longer working and the way the unit was designed it could not be replaced.  Butch happened to have an identical unit, so I used it as the replacement.

Old patio light fixture after being removed from the side of the coach.  Not pretty.

Old patio light fixture after being removed from the side of the coach. Not pretty.

The old unit was not removed from the coach when it was painted.  This was a nice idea at the time as it provided a paint seal on the top and both sides where the unit met the side wall of the bus.  Unfortunately, removing the unit required me to cut the paint seal with a very sharp knife.  The unit was secured with two screws, but it was stuck to the side of the coach with a generous amount of automotive putty.  Most of it came off with the fixture, but not all, so after I cut the two wires and removed the fixture I had to carefully scrape the rest of it off using the thin end of a wood shim.

I checked the voltage at the two wires coming out of the wall and I definitely had 13 VDC controlled by the same switch that turns the lighted entrance handle on and off.  I prepared the back of the new fixture using new automotive putty to create a seal all the way around the back at the outside edges.  I also placed a ring of putty around each of the screw holes in the back and the access hole for the wires.  I attached shielded spade lug disconnects to all four wires, held the fixture in place, and connected them.  I pressed the fixture into position, lined up the screw holes, and secured it.  I put the two F8T5 florescent tubes back in, snapped the cover back in place, and made sure the on/off pushbutton switch on the bottom was in the on position.  I then applied a bead of NAPA RTV Black Silicon Rubber sealant along the top seam and the two sides.  (Sorry Michele, but I had to make sure it was not going to leak.)

The switch that controls this light is one of three in a 3-gang box next to the passenger seat and is the one closest to the entrance door.  I had removed the cover plates last week so today I took another look and it appeared that the other two switches did not have any wires connected to them.  I removed them and that was indeed the case.  I think tomorrow I will re-wire this so the first switch controls only the lighted entrance handle and the second switch controls only the patio light.  If I cannot figure out something to control with the third switch I will probably leave it out and get a new cover plate that has two switch openings and a blank, assuming I can find one.

With the patio light project done Fonda helped me remove the fan belt and the two A-C compressor drive belts from the engine in our bus.  We put the two compressor drive belts (NAPA CG-96) back on but reversed their position.  The inside one seemed loose compared to the outside one last week and we wanted to see if switching them would fix that problem.  We then installed the new fan belt that I ordered/received last week.

I started the main engine and let it run for a while on high idle with the air-conditioning turned on to put some load on it.  The CG-96 that was now on the outside of the pulley still appeared to be looser than the other one, so I think I will order a replacement set.  The new fan belt ran very smoothly.  I turned the A-C off, dropped the idle down, and shut off the engine.  I started to close the rear access hatch but found that it was stiff and made a sound like an elephant trumpeting.  I sprayed some WD-40 on all the hinges and on the piston rods for the air springs.  I then put a small amount of NAPA Syl-Glide on the piston rods, worked them up and down a few times, and wiped off any excess.  The hatch now opens and closes smoothly and quietly with less effort.

Butch pressure washing the radiators for his fan coil heat exchangers.  MC-9 (L) and H3-40 (R).

Butch pressure washing the radiators for his fan coil heat exchangers. MC-9 (L) and H3-40 (R).

While I was lubricating the hatch Butch was using a pressure washer to clean the radiators (heat exchangers) for their fan-coil units.  As long as he had it out, he sprayed around all of our front windshield seals while I looked for leaks inside.  We found three for sure.  One was in the upper inside corner of the lower driver-side windshield between the center pillar and the seal.  The second one was in the lower outside corner of the upper driver-side windshield between the seal and the glass.  We were not able to identify the point(s) of entry for the third one but it appeared to be somewhere above the upper windshields near the center pillar, a least that was where the water was coming in on the inside.  I cannot see the underside of the front cowling in that area and there are lots of places water could come in: five front marker lights, two upper windshield mounts, and perhaps a dozen screws on top of the front roof holding various things down.

Leaks are annoying and potentially destructive so I am still pondering what I want to do.  We have new windshield seals but have had trouble finding someone locally to install them.  For one thing, the bus really needs to be inside for that work and most glass shops, including ones that work on “semi tractors,” do not have overhead doors high enough for the bus.  I may make judicious use of the NAPA RTV Silicone Rubber sealant or I may just use black tape as a temporary fix.

When we were done checking the windshields I used the pressure washer to clean off the coach as best I could.  The last time it was cleaned was right before we left Williston Crossings RV Resort in early April and it had accumulated a few miles, bugs, and dirt in that time.

Because the weather was so nice Butch decided to replace a short section of badly deteriorated coolant hose on their engine rather than risk having it fail on the road.  He shut some valves to isolate the engine from the coolant lines that provide heat to the coach and drained quite a few gallons out of the engine (almost three 5-gallon buckets).  The old hose turned out to be extraordinarily difficult to remove. The new piece was no easier to get in and required modification of two parts.  This was definitely not a job you want to do on the side of the road in any kind of weather.

While Butch and Fonda worked on the coolant hose I tinkered in the dashboard area of my bus.  First I replaced a couple more bulbs in illuminated switches.  I then pulled the CB radio out of the dash to see how the coaxial cable (transmission line) was marked.  That allowed me to identify the other end in the old ceiling-mounted TV cabinet behind the driver’s seat.  I also looked around in that cabinet for the other end of the coaxial cable that was once connected to the antenna for in-dash AM/FM radio/cassette/CD player.  I did not see anything that looked right, so I pulled the radio out of the dash (actually the whole panel along with four switches) to get the identifying marks off of it. Even with that information I was not able to locate the other end of the cable.

Working on the bus and living in the bus are often not compatible.

Working on the bus and living in the bus are often not compatible.

By that point it was 6 PM and we had weather approaching from the southwest.  Clouds had moved in, greatly reducing our natural light, and gave the first indications of the rain that was forecast for the evening hours.  I will look again for the radio antenna cable tomorrow as I have a TuneTrapper antenna that I want to install on the underside of the front roof via the old TV cabinet and I need to plug it into the cable that goes to the radio.

I had a small glass of Moscato while I prepared my dinner.  I fixed a salad of power greens with peanuts, dried cranberries, and fresh diced onions and finished a bottle of Ken’s Sweet Vidalia Onion dressing.  I grabbed a can of Amy’s “No Chicken Noodle” soup, some crackers, my jar of peanut butter, and some ICE brand water and went inside to eat with Butch and Fonda.  I returned to the coach after dinner, cleaned up my dishes from the day, and bagged up my recyclables.  We bought a small container on Saturday that is intended for storing pet food but it has a gasketed lid with a snap latch that I thought would make a nice mouse-proof kitchen trash can.  (I figure the mouse will leave if it cannot get any food.)  Alas, the container does not fit in the base cabinet under the kitchen sink so it will likely end up being used for its intended purpose after all.

2014/10/28 (T) Under the Bus

In corporate life “getting thrown under the bus” is not a good thing, but if you are the owner/builder/maintainer of a converted highway coach, getting under the bus will eventually be a necessity.  Today was finally my day, but not until mid-afternoon.

The forecast for today was for rain in the morning tapering off to zero by noon and then turning sunny; and that is exactly the day we had.  Knowing that the morning would be wet, I took a couple of Tylenol PM last night and slept in a bit later than normal.  After my usual breakfast of granola, orange juice, and coffee, with some spicy V8 thrown in for good measure, I set to work on the interior of the old TV cabinet located above and behind the driver’s seat.

Yesterday I pulled the CB radio and the AM/FM radio out of the dashboard and identified how the coaxial antenna cable for each one was marked.  I located the cable for the CB in the TV cabinet but was not able to find the one for the AM/FM radio.  I got my twin tube florescent worklight and rigged up a couple of zip ties with mounting tabs to hang it from.  I looked again this morning but still could not locate the AM/FM radio antenna cable.  Rather than waste time not finding it I decided to organize the inside of the cabinet which has had an outlet strip, an OTA TV antenna controller, the Wi-Fi Ranger POE adapter, DC power supplies, and a mess of cable that has been lying around in it for a couple of years now.

Using the tab mount zip ties I coiled each cable and secured it to one of the two side walls.  The OTA TV antenna cable (signal and control) was very long, so I wound it around a 5-gallon plastic bucket to make a nice round, large coil.  The outlet strip had mounting slots on the back, so I mounted it to the wall on the lower half of the back of the cabinet.  The upper half of the back is open to the area above the driver and entrance stairs and under the front cap of the roof.

Late in the morning I took a break from the TV cabinet work and helped Butch cut access panels out of a 1/8″ aluminum sheet that will cover the inside of their entrance door.  We tried using a sabre saw but the only blade we had was not sharp enough or was the wrong type.  We used his Ryobi cordless reciprocating saw with a metal cutting blade and it made much quicker, and surprisingly clean, cuts.  I then used Butch’s angle grinder to round the corners of the sheet and remove burrs from all of the cut edges.

I stopped for lunch around 2 PM and enjoyed a hummus and onion sandwich.  By the time I was done the day was as warm and sunny as it was going to get so I decided to scoot under the bus and measure the ride height linkages.  This was the first time I have been under the bus.  Please note that the bus was supported on four stands that Butch made for me out of 1/2″ steel plate and 4″ square steel tube with 1/2″ thick walls.  In other words, the bus was not supported by the tires and air springs so the bus would not move if there was a failure in one of those components.

H3-40 front axle ride height valve and linkage.

H3-40 front axle ride height valve and linkage.

The linkage in the front was easy as I could slide under the bus just in front of the driver side steer tire and then sit up between the front tires with lots of room to work.  The linkage is directly above the center of the front axle and connects the axle to a lever arm on an air valve that determines the amount of air that goes into the front airbags (when in drive mode), and thus sets the suspension at “ride height.”  Butch wanted me to remove the linkage but I chose not to.  As it turned out I should have and will probably slide back under the front tomorrow and remove it.

The rear linkages were much more difficult.  First of all, there are two on them, one for each end of the drive axle.  They are located just inside the body panel directly in front of the outside dual drive tire and are covered by a protective shield.  The shields are bolted on at four points, none of which are easy to reach and one of which ultimately required me to get under the rear end of the bus.  Access is much tighter here because of:  1) The dual drive tires on each end of the drive axle; 2) The drive axle carrier, and; 3) The exhaust pipe for the Aqua-Hot which runs under the bus from the passenger side to the driver side where it ends up next to the exhaust pipe from the generator.  I was able to scoot under the bus from the passenger side just in front of the drive tires, but just barely, and once I was under far enough to sit up there was much less room to work compared to the front.  Because of the difficulty of getting to the linkages to make an accurate measurement of the center-to-center distance between the mounting bolts I went ahead and unbolted them and removed them.

The linkages consist of a length of metal rod approximately 1/4” in diameter with a rubber bushing on each end that looks a bit like and eye-bolt.  The rubber bushings slip over the ends of the metal rods and are secured with band clamps.  They appear surprisingly fragile given the critical nature of their function, and Butch has already had one that was only a couple of year’s old break on their coach.  He ordered metal versions in both left-hand and right-hand threads and is going to assemble replacements using threaded rod and stop nuts.  With a left-hand threaded bushing on one end and a right-hand threaded bushing on the other end we will be able to turn the threaded rod one way to increase the distance between the two mounting bolts and the other way to shorten it, affecting both ends equally in the process.  The stop nuts will lock the bushings relative to the threaded rod so they do not move in operation.  All-in-all this will be a neat little project.

In spite of the lovely weather Butch needed to get to the NAPA store in Logansport before they closed at 5:30 PM.  At 4:30 PM I wrapped up my work with the linkages, put all of my tools away, washed up, and grabbed my wallet, cell phone, and shopping list.  We got to the NAPA store a little after 5 PM and took care of our business there.  We then headed to the O’Reilly’s Auto Parts store for a few other things.  I called Linda and chatted briefly with her and was relieved to hear that she sounded, and was feeling, considerably better.  Butch called Jaral Beatty to see if he had finished cutting the oak valences for the front of their bus.  He had, so we swung by Jaral’s shop to pick them up.

Front flat-panel TV/monitor with cabinet door closed.  Look ma, no wires!

Front flat-panel TV/monitor with cabinet door closed. Look ma, no wires!

While we were at Jaral’s he ripped a nice piece of 3/4″ thick oak for me to just under 3″ wide.  The piece was about 4′ long and he did not charge me for it.  I plan to attach this piece of wood to the center windshield pillar and use it as a mounting plate for a compass, flat panel monitor, PressurePro TPMS receiver, and the mirror that is currently mounted at the intersection of the four windshields.  I have to do this, of course, in such a way that it does not obscure my vision while driving.  From Jaral’s shop we went to Home Depot where I bought a thin (1″ thick), 13″ long, under-cabinet, single-tube florescent, AC powered light fixture.  I also got a blade for my Porter-Cable oscillating saw.

When we got back to Twelve Mile a little after 7 PM Fonda started preparing their dinner and I did the same.  I had a nice salad of power greens with onions, dried cranberries, and roasted peanuts topped with a sweet and sour dressing.  I also had a bowl of Thai Kitchen spring onion soup, some canned pears, and half a piece of pita pocket bread.  After dinner I washed my recyclable containers and went back to the coach for a while where I cleaned and dried a few utensils.  I then mounted the new light fixture in the TV cabinet.  As I expected, it provides very nice illumination for the entire inside of the cabinet.

Depending how the day goes tomorrow I plan to continue working in the front TV cabinet.  I would like to mount the TuneTrapper AM/FM antenna and get it connected to the AM/FM radio.  Butch’s brother, Tom, is coming over sometime during the day to winterize his motorhome.  Butch called and asked him to bring the faceplate from an old Kenwood radio that he had that was very similar to the one in our dashboard.  The backlight illumination bulb is burned out on ours.  I also need to create an access slot in the door for cables to pass between the back of the flat panel TV (which is mounted to the outside of the door) and the inside of the cabinet.  To create this access slot I will have to drill holes centered along a line and then use Butch’s root-zip tool to connect the holes into a slot.  The bushings for the ride height linkages are supposed to be in tomorrow, so we will be making a morning trip towards Kokomo to pick them up.  Butch is also trying to tap into the engine coolant loop that provides OTR heat for their bus as part of the Oasis Combi installation, so it is likely to be a very full day.

2014/10/29 (W) Outside In

My main project today was once again the front TV cabinet only this time the focus was on cutting a horizontal opening in the door behind the flat panel TV that is mounted on the outside of the door.  The approach I used was to drill two 1″ holes, one at either end of a horizontal line, and then use a roto-zip tool as a mini-router to connect the tops of the holes together and the bottoms of the holes together, creating a horizontal slot with rounded ends.  The slot is below the horizontal center line of the TV set and offset to the left (as viewed from the front of the TV) to line up with the area on the back of the set where the power, video, and data cables exit downward.  The position of the slot allows them to gently bend and pass from the outside of the cabinet to the inside of the cabinet where they get connected.  This also allows the cabinet door to be closed and latched with none of the cables visible.  It sounds simple but it took me a good part of the day to get it done.  We have a second flat panel TV in the bedroom mounted on a similar door that covers another old TV cabinet.  Cutting a similar slot in that door is on my task list for tomorrow.

Front TV cabinet; making use of the space where the 10" CRT was mounted.

Front TV cabinet; making use of the space where the 10″ CRT was mounted.

When I wasn’t working on the TV cabinet I spent a few minutes learning how to use an air-powered cutoff tool and giving Butch a break by using it to help cut off a piece of the center tunnel sidewall in their passenger side front bay.  Butch is removing this panel in order to gain access to the engine coolant lines that provide heat for the bus when it is underway.  He needs to tie a stacked-plate heat exchanger into these lines as part of the ITR Oasis Combi hydronic heating system installation.

Butch spent most of his day working on their Suburban installing a Ready-Brake auxiliary braking system and extra rear lights for towing.  I checked in with him from time to time, but he was either in the middle of one-person tasks or had Fonda helping him.  Late in the afternoon we rolled his Ryobi belt sander out of the warehouse and used it to sand his two valence boards and my piece of oak that we picked up yesterday from Jarel.  We had to change the sanding belt and it took us a few tries to get it right, but it did a nice job on the boards once we had a good piece of sandpaper on it.

By the time we finished it was twilight and very cool.  Tom and Tracy showed up about then to winterize their motorhome.  There was a locked cover over the fresh water fill connector and none of Tom’s keys would open it.  I got a long flat-blade screwdriver and was able to slip it up under the cover and pop the lock.  I left the winterizing to Butch and Tom and retreated to my coach to putter and contemplate (and eat) at a lovely 67 degrees F.  The Aqua-Hot has been working very reliably, cycling on and off automatically in response to the space and water heating demands of the coach.

Tom brought an old Kenwood car stereo that he got from Butch a while back.  Although similar in appearance to our Kenwood dashboard radio, it was not similar enough.  The electrical connector on the back of the removable faceplate was in a different location than ours.  I had a Singapore Noodles dish in the coach and then made a salad to take into the house and dine with Butch and Fonda.  It was after 9 PM by the time we were done eating and I turned in for the night shortly thereafter.