Tag Archives: OTR HVAC interior ducts (H3-40)

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.

 

2015/10/07 (W) The Root Cause

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.

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.

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.

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.

 

2015/09/11 (F) Reassembling

I’m sure everyone who is old enough to remember September 11, 2001 remembers exactly where they were and what they were doing that morning.  Along with Pearl Harbor and the Invasion of Normandy 9/11 is certainly one of the most somber days of the year.

I was up late last night so I did not get up until 8 this morning.  I took a warm shower which was very refreshing.  (It was chilly overnight.)  I then fed the cats and made the coffee.  Linda got up and washed the blueberries, and we had granola for breakfast.  She worked at her desk while I researched expanded metal mesh.  It is readily available online in a wide variety of forms and basic stuff is apparently in stock at The Home Depot in Howell.

Linda needed to make deposits at two banks in Howell so we added The Home Depot to our errand run.  We picked up two small sheets of decorative metal screen and some other miscellaneous items.  By the time we got back to the car I had already decided that would probably not use the metal screens but we took them home anyway.

We finally got busy in the bus at noon.  Linda started putting the drawers back in and changing the handles in the cabinets.  It turned out that we needed #8-32×3/4 machine screws for at least some of the cabinet doors.  It also turned out that every drawer in the coach fit in a unique location.  In most cases it was obvious where a drawer went, but not all.  While she dealt with that I worked in the bathroom.

A portion of the OTR HVAC return air grill in the bathroom had been cut out, presumably by Royale Coach, but was not being used to pass plumbing or wiring.  It was yet another point of access for mice to get into the coach via the HVAC system (if that’s how they are getting in) but I wanted to seal it up while I had the chance (just in case it was).  I wanted to preserve the return air flow functionality of that area, however, buy covering it with expanded metal mesh.  I had salvaged some from the old furniture but had already used it as temporary screening on the HVAC duct by the living room sofa.  I had to uninstall a piece from there and cut it down to the right size.

It took way too much time to find my metal shears but I eventually did, in a tub with garden tools of all places.  I hate it when that happens.  It was an inauspicious and inefficient start to the day’s work.  Some of the inefficiency in this project can be directly attributed to the fact that we are still not fully moved in to this house after 2-1/2 years and do not have all of the tools and supplies unpacked and organized in a proper shop.  We spend too much time looking for things and even more time driving to the store to buy something we probably already own but cannot find.

The Microphor LF-210 air-flush toilet set back in place in the bathroom.

The Microphor LF-210 air-flush toilet set back in place in the bathroom.

We moved the toilet from the bedroom storage box to the bathroom and set it approximately in place.  We left the wood cover off the HVAC/wiring chase and then moved the toilet into position as far as possible.  Final positioning required the drain to be connected.  It was difficult to disconnect and even more difficult to reconnect.

The toilet outlet and the drain pipe get connected by a rubber sleeve with a stop in the middle.  A metal compression sleeve with two integral worm gear band clamps then goes around the rubber sleeve.  In order to get this assembled I left the compression sleeve off and got the rubber sleeve over both pieces.  We were the able to move the toilet back and make sure the two pipes were fully seated but it was a lot harder than this makes it sound and took a lot longer to do that it did to write these few words.

To get the compression sleeve on I had to unwind the worm screws until the bands popped out.  I spread it open and slipped it over the rubber sleeve.  I then put a zip tie around it to compress it and hold it in place while I bent the compression bands around and back into the worm gear.  Once I got them to “bite” I was able to use a 5/16ths socket on a very long extension to reach inside the back housing and tighten the bands.  Again, it was a lot harder to do than this description suggests and took quite a while to accomplish.  There is very little room to work inside the back of his toilet and the drain/clamps are at the very bottom near the floor with the only access being from above.

Next was hooking up the water and that was ordeal in its own right as I could not get the water line to line up with the plumbing in the toilet.  I eventually realized that the tile floor extended back over the bottom flange of the HVAC duct where the water supply line used to sit.  We heated the tile behind the toilet with a hair dryer and I then used sharp utility knife to trim it.  The nine inch piece of Qest pipe with nuts on both ends still did not want to line up with the supply pipe or toilet connection.  I eventually got it connected but it was a struggle.

The vacuum breaker (L, in my hand) and the air/water sequence valve (R) as viewed looking straight down into the back of the toilet.  The Microphor LF-210 toilet does not have a water tank.  The entire back of the toilet is full of valves, air lines, and water lines.

The vacuum breaker (L, in my hand) and the air/water sequence valve (R) as viewed looking straight down into the back of the toilet. The Microphor LF-210 toilet does not have a water tank. The entire back of the toilet is full of valves, air lines, and water lines.

Last, but not least, was the air.  The Microphor LF-210 is an air-flush toilet that uses 1/2 gallon of water per flush.  I started the bus to pressurize all of the air systems.  Once the auxiliary air tank was full I had Linda hold a rag over the open end of the air line and gave it five good blasts of air to blow out any debris that might have gotten in there.  I then shut off the air supply and connected the air tube to the flush actuator.  I turned the air supply back on, turned on the water pump, and opened the water valve.  Everything looked OK so I flushed the toilet.  Everything worked but we had a leak between two components where we had never had a leak before; at least not as far as I knew.  It was 4:30 PM and it was now obvious that we were not going to accomplish most of what we planned/needed to get done today.

The leak was between two of the fresh water components, the air/water sequence valve and the vacuum breaker.  The air/water sequence valve has a pipe with an O-ring that slides into a matching hole on the vacuum breaker and the leak was at that junction.  The vacuum breaker has a second hole, at a right angle to the first one, which slides over another stub with an O-ring that is screwed into the back of the toilet (inside) and feeds water to the bowl.  I ASSumed that the leak was due to the O-ring between the two parts having failed.  All told I spent another 6 hours on trying to fix the leak, including trips to various stores for O-rings, etc.

About 1/2 hour before I quit working for the night it occurred to me that the leak might not be the O-ring as the pipe with the O-ring is threaded into the air/water sequence valve.  It’s a pipe, so it’s hollow, but it threads into something and is smooth on the outside with nothing to put a wrench on.  Looking in the end, I saw that internally it was a hex socket.  I got my Allen wrench sets to see if I had the right size, but I didn’t.  My hex keys only go to 3/8″ and this was bigger than that.  It was 10 PM and I had spent 10 hours working on the installation and repair of the toilet without successfully completing the task.  Some days are like that and you have to take them in stride.  If you can’t (or won’t), converting (or reconverting) a bus is probably a bad choice of hobby.  For that matter so is owning a house and trying to maintain it yourself.  I guess life really is easier if you can just throw money at problems.

Given the progress of the work today we realized that we would have to delay our departure for Edwardsburg/Elkhart until at least Tuesday morning, and might not be able to leave at all if I could not get the toilet repaired without ordering parts.  We considered alternatives, including me taking the bus by myself to Coach Supply Direct and then bringing it home, skipping the GLCC rally in Elkhart.

 

2015/09/06 (N) Grouting

We got up quietly at 7:30 AM as Madeline was still sound asleep.  Linda did not want to let her sleep too long and get off schedule so I got the “all clear” to grind the coffee beans just before 8 AM.  I made the Costa Rican half-caff because I am trying to use it up so we can replace it with something we like better.  Madeline emerged with Grandma Linda a few minutes later.  After stretching they decided to sit quietly on the living room sofa and read stories while everyone woke up and the adults enjoyed our coffee.

Sometime between 9:30 and 10 AM we left for the Howell Farmers Market.  We walked from one end to the other, with Madeline in her stroller, scoping out this week’s bounty. We then walked back through and Linda bought a few things including hard stem garlic which we had never seen before.  We stopped and chatted with our favorite vendor, Marjorie.

When we got home and put the produce away Linda prepared a snack lunch for herself and Madeline.  The two of them then went on an outing to the farm at Kensington Metropark (KMP) while I stayed behind to work on bus projects.  I decided to start by finishing the assembly of the pieces for the built-in sofa.  I attached the center support for the return air shelf as follows:

  • I determined the center of the long edges of the shelf and drew a line between them.
  • I carried these center marks to the other side and then measured 3/8″ to either side.
  • I connected corresponding marks to create a pair of parallel lines 3/4″ apart and centered on the underside of the shelf.
  • I placed the support in position, determined its fore-aft position, and marked the ends.
  • I then marked a piece of scrap wood, cut it into four pieces, and used them to hold the support in place; two long pieces the same length as the support, and two short pieces across the ends.
  • This allowed me to turn the shelf right side up with the center support held in the correct place and then mark and drill countersunk pilot holes for the screws.
  • I removed the support piece, sanded off any rough spots, put Titebond II wood glue on the edge, and replaced it between the temporary blocking.
  • I stood on the shelf to force the pieces together and ran all the screws down tight.
  • I then removed the temporary blocking.

After sleeping on it last night I decided I would attach the plenum/support boxes to the vertical front panel and the wood wire chase on top of the HVAC chase rather than to the adjacent cabinets or to the floor.  That meant I could go ahead and assemble them as complete, single units.  Easier said than done.

Even though I used right angle corner clamps the two halves I built for each box did not want to go together perfectly.  I managed to get one of them assembled but could not complete the other one by myself.  The problem was that I needed both hands to pull the pieces into alignment and two more hands to operate the drill and screw gun.

By now it was 1 PM, which is Madeline’s normal nap time, but they were not back from the Metropark yet so I gathered up all of the tools and materials I needed to grout the floor tiles in the bus.  That included the special Armstrong S-288 Glacier White sanded vinyl grout, a flat blade screwdriver, the 4″x8″ hard edge float, the smaller margin trowel, the 2″ putty knife (wall scraper), the ScotchBrite sponges, the Revel scrubber, two large buckets for rinse water, paper towels, a large cloth towel, and paper bags.

Madeline pets one of the sheep at the Kensington Metropark animal farm.

Madeline pets one of the sheep at the Kensington Metropark animal farm.

Since Linda and Madeline had still not returned I had a few pretzels with hummus.  They finally got home around 1:30 PM and I heard all about the farm and the animals Ms. M got to see and touch.  The 2-day old piglets were apparently a big hit but so was the playroom.  It was a good outing and I wish I could have gone but I got stuff done that needed to be done.

Madeline finally laid down for her nap at 2 PM but Linda could not help me with the tile grouting as she needed to be within earshot of Madeline’s bedroom.  I decided that we could not afford any further delay for this aspect of the interior remodeling project and resolved to do it by myself.  Without Linda to walk me through the steps, have materials ready, and clean the tools, I needed to be very clear about the steps and their timing.  I must have read the directions on the container of grout a dozen times in an attempt to internalize them but they just would not stick with me.  I needed a spray bottle for water so Linda found one for me.

The afternoon was very warm so I turned off the air-conditioning in our home library, closed up the coach, and turned on two of the three air-conditioners, making sure they were on opposite legs of the electrical service.  I staged all of the stuff in the bedroom storage box as I planned to start on the back side of the bed in the driver side corner by the head of the bed and work my way out.

I finally got started at 2:30 PM.  The grouting involved a specific set of steps that got repeated many times as the directions said to only do 6 – 10 sq. ft. at a time.  That range had to do with the time required to apply and strike the grout, setup time (3 – 8 minutes), misting with water, waiting 20-30 seconds, scrubbing, and finally wiping with a square edged cellulose sponge.  I had to divide the U-shaped bedroom floor into six sections and it took me until 5:30 PM to do that much so my average time was 30 minutes per section, each of which was smaller than 6 square feet.

I took a short break, had something to drink, and checked with Linda on the timing of dinner.  We settled on 6:30 PM and I returned to my grouting.  I had to do the bathroom floor in two sections, which got me into the hallway and joined up with the work from the bedroom.  I went in to clean up for dinner and was greeted by the smell of something baking.  Madeline wanted to make cupcakes so Linda assembled the ingredients and walked her through the steps, letting her do as much of the work as possible.  For not even being three years old yet she is very interested in cooking, but only if it is something she will get to eat! 🙂

Dinner was vegan cheeseburgers, corn-on-the-cob (from the Farmers Market), left over black beans and edamame, and sliced pears.  I worked in the bus from 7 to 8 PM and finished the hallway as far as the bend that transitions into the kitchen.  I cleaned all of the tools and sealed the grout container using Cling-Wrap pressed down onto the surface of the grout to keep air away from it, and locked up the bus.

I washed up and turned on the Yaesu FTM-400 2m/70cm radio in the ham shack while Linda helped Madeline take a bath.  Steve, N8AR, was serving as net control for the weekly SLAARC information net and had already started the net but not yet called for check-ins so I got to participate in the entire net.  We had a small group this evening, most likely due to it being a holiday weekend, but it was still a good net.

I came upstairs to have dessert with Linda and Madeline; chocolate cupcakes (vegan) with sprinkles.  Yum.  I then returned to my office to re-read an article I wrote about replacing the speedometer in the bus and editing it to indicate where the pictures should be placed.  I dealt with several BCM related e-mails and then came upstairs.

Madeline was in her pajamas and sitting in her portable bed while Linda read a story.  She decided that she wanted me to read a couple stories too, so I did.  We got her tucked in with her stuffed animals arranged at the four corners of her bed, turned on the night light, and left her to fall asleep.

I opened the bottle of Apricot wine that Brendan and Shawna picked up from Leelenau Cellars and we each had a small glass.  I worked on this post while Linda cleaned up the kitchen.  It had been a long and very tiring day for both of us but a very satisfying and productive day as well.  We don’t mind that kind of tired.