Tag Archives: Tarheel screwdriver antenna

2015/01/01-07 (R-W) Q 2015 W1

2015/01/01 (R) Hola 2015

The salt restraining tube for the water filter housing.  The slotted end (R) goes down and the o-rings sit in the other end.

The salt restraining tube for the water filter housing. The slotted end (R) goes down and the o-rings sit in the other end.

Having stayed up later than usual last night to see the old year out and welcome the new year in we were in no hurry to get up this morning, especially given that the temperature outside was in the upper 20s.  But Linda said she would make her yummy vegan cinnamon rolls for breakfast so I felt obligated to get up and eat them.  Besides, it’s my job to make the coffee.  The rolls took quite a while to make and we ended up having them for brunch, but they were worth the wait.

I spent much of the morning looking for new games in the iStore.  I downloaded a dozen free ones and then started trying them in turn.  Most of them immediately tried to sell me a full version or ran a full-screen advertisement each time I tried to start a new round of play.  If they did that I immediately deleted the app.  I cannot imagine what makes a game developer think someone with tolerate that more than once.  At some point I realized that my AppleID was still associated with an old e-mail address so I initiated the process of changing it.  The process was not as seamless as I thought it could/would/should be, but I eventually got it sorted out.  Or as they say or Doc Martin, “sorted.”  As it turned out my credit card information was also out of date so I updated that as well.  Obviously I do not make iStore purchases very often.

I needed to regenerate our portable water softener even though it was 48 degrees F outside in the shade.  It was, however, comfortable enough in the sun to be able to work.  I started at noon cutting the plastic drain pipe that I bought at Herb’s Hardware the other day to a length of 10″ which is the length of a standard water filter.  I cut eight 3/8″ slots in the bottom end of the tube and got an O-ring from Butch to fit in the swaged upper end.  The purpose of the tube is to hold salt so that incoming water is required to pass through it to get to the softener but the salt crystals cannot actually wash into the softener.

Linda helped me transfer the contents of a 40 pound bag of solar salt to several two-gallon zip lock bags.  I then put a small quantity of salt in a one-quart zip lock bag and gently smashed it with a two-pound sledgehammer, although as I write that it seems to be something of an oxymoron.  I inserted the tube into the removable filter housing, slotted side down, and poured the salt around the outside of the tube.  I smashed a second bag of salt and added it to the housing.  I put the housing back on the filter head and slowly ran water through the softener for almost two hours.  I got a water hardness test strip from Butch and tested the output of the softener.  It was still showing 7 grains of hardness, exactly the same as two days ago.  It appeared that the regeneration process had not had any effect.  Bummer.

I discussed the situation with Butch and he suggested I back flush the softener.  To do that I needed a hose with female hose fittings on each end.  This is the kind of hose used to hook up a washing machine but neither one of us had one with us.  Butch, however, had a female-female adapter which allowed me to connect a male hose end to a male fitting on the outlet of the water softener.  (Backflushing literally means running water through the softener in the reverse direction to flush out any debris that may after gotten in through the normal inlet.)

The salt retaining tube in the filter housing with salt around the bottom outside and the o-ring visible at the top.

The salt retaining tube in the filter housing with salt around the bottom outside and the o-ring visible at the top.

After backflushing the softener I tried regenerating it again.  This time I used a 26 ounces of fine grain non-iodized table salt.  With my homemade diverter tube still in place I added the salt around the outside and screwed the housing back on.  I let the salt sit in the housing for 20 minutes to start to make a brine and then ran water through the softener until I got a very salty taste at the output.  I then shut the outlet valve and let it sit for 20 minutes.  When the time elapsed I ran water through the softener for another 15 seconds, checked it for saltiness, and shut the outlet valve.  At the end of another 20 minutes I ran water through it at a very slow rate for 20 minutes and then checked it again for salty taste.  It was still slightly salty and as it was getting close to sunset I decided to let it sit overnight.  I will finish flushing it tomorrow and check the hardness again.

While I was fussing with our water softener Butch recharged theirs in about 30 minutes.  When he tested the water at the end it indicated zero (0) grains of hardness; completely softened.  Their softener is different from ours and the regeneration procedure is very straightforward and apparently works.  For now I need to figure out a guaranteed procedure for regenerating ours, but long-term I need to figure out some other arrangement of just get a different softener.

The arrangement I am considering would be in conjunction with redoing the water bay. With a different arrangement of tanks I could create space in the bay for the softener, multiple filter housings, and associated plumbing.  I could set up an arrangement that would divert the incoming water (after the first/sediment filter) through a clear filter housing into which I could put the salt.  That clear housing/head would be permanently modified to force water through the salt and allow me to see when the salt was gone.  It would also eliminate the need to remove and reinstall the filter the way I have to now.  Alternatively I could put a tank between the filter housing and the softener (instead of the clear housing) and use it as a brine tank.  If the tank was big enough to hold a 40 pound bag of solar salt it would work just like a home softening system.  Water would sit in the tank with the salt for days so that the brine was ready to use when it was time to regenerate the softener.  I could even rig up a separate pump just for pumping the brine into the softener.  I’m going to give this a lot of thought before I start changing things around, but last winter in Florida and this winter in Quartzsite have made it very clear that hard water is a problem and we need a very effective and efficient way to deal with it.

While I worked with the water softener Linda began preparing a Tex-Mex bean soup for dinner and then went for a long walk.  She finished making the soup when she got back while I took a short nap.  It cooled off quickly as the sun set and nothing is quite as satisfying on a cool evening as hearty, hot soup.  It also had a bit of red pepper heat which was a nice bonus.  It was really good soup.

I had a few e-mails from Gary at BCM and a nice follow-up e-mail from Kathy at the Michigan Assessment Consortium.  She attached a copy of their holiday letter so I attached a copy of ours in reply.  I spent a little time browsing websites for OTA TV antennas and turbo boost gauges and finally went to bed without resolving what to do about either thing.  I have a lot of nights that end like that.

2015/01/02 (F) Crazy Days In Q

Contact is established with our cat, Jasper.

Contact is established with our cat, Jasper.

The “show” at Desert Gardens officially opened yesterday and runs through the end of February, so Quartzsite is quickly be transformed into a crazy place.  We were chatting with Butch, Fonda, Jim, and Barb after breakfast and Barb reminded us that starting now driving and parking “downtown”, and especially along Kuehn Street south of I-10, during the day will be difficult to impossible.  She offered to drive us down in the golf cart and come pick us up if we did not want to walk.  She also told us that many vendors will hold purchases for pickup at the end of the day.  We exchanged cell phone numbers, which we had not yet done since they arrived.  She suggested that if we wanted to eat out we should go early or right before closing as we might not be able to get seated/served otherwise.  There’s no doubt that we have lucked out on our arrangements this winter, and the situation just keeps getting better.

Linda was browsing on her iPad and discovered an all vegan grocery store in Rancho Cucamonga, California; the largest all-vegan grocery store in the world.  I looked up Rancho Cucamonga on Google Maps and it is located about half way between Los Angeles and San Bernardino.  Based on the speeds I like to drive (often just below the speed limit or 68 MPH, whichever is less) it looks like a four hour drive one-way from Q.  That’s obviously too far for a regular grocery run, but we might make a day trip in that direction sometime this winter and find the store while we are over there.

One of the things I did after climbing in bed last night was spend a little time looking at the Sure Marine Service website.  SMS is a major supplier of repair parts for Webasto diesel-fired hydronic systems headquartered in Seattle, Washington.  After studying their parts diagrams I became unclear (and concerned) as to whether the burner we removed from Butch’s old unit was a DBW2010 or a DBW2020.  They are very similar but not identical.  I am almost certain that our original burner is a DBW2010, but our AHU-xxx Aqua-Hot is so old that the model number is no longer referenced on the website and model specific documentation, like a service manual, is not available for download.

The reason I was looking at the parts diagrams was to identify the bearing kit for the blower as I wanted to order two of them today.  What I could tell from the website was that the 2020 is a higher BTU output burner and so one of the differences is that the 2010 uses a 0.35 GPH nozzle while the 2020 uses a 0.60 GPH nozzle.  That alone might account for why we seem to have poor combustion, although even money is still on bad bearings.  The unresolved issues and the inability to investigate at midnight did not make for a good night’s sleep.

I have the Aqua-Hot service/repair manual for the unit I bought from Butch, both on paper and on my iPad, so I spent some time this morning looking at the iPad version.  I could not tell if they used the same bearing parts so I did not order anything today and won’t until I can determine model numbers.  I asked Butch if he knew which burner was in the Aqua-Hot I bought from him, but he did not.  The service manual shows a Webasto label that identifies the burner model, but does not show where the label is located.  More investigation was needed.

After I got dressed I e-mailed Bill Gerrie (RetiredBusNut) in Ontario, Canada with questions about gauges and sending units for our bus engine and transmission.  I then started dealing with the water softener.  Linda returned from her walk and started preparing lunch, so I emptied the filter housing of the little bit of salt that was still in the bottom, rinsed it clean, re-installed the filter, and let it run for 20 minutes to fully flush out any residual salt water.

Linda made a warm garbanzo bean and kale salad for lunch with lemon juice and garlic.  It was the first time she had tried this recipe and we both agreed it was a keeper. After lunch I tested the hardness of the water coming out of the softener and it registered on the test strip between zero (completely soft) and 1.5 (definitely soft) so I dumped the remaining (hard) water in the fresh water tank and refilled it with 120 gallons of nice, soft water.  After the tank was full I retested the water coming out of the softener and got the same reading as before.  Finally, some good news on the water softener front.

With water softening taken care of (for now) I did an online search for a panoramic camera tripod head.  I really like shooting panoramas and the Microsoft Image Composite Editor (MS-ICE) does a remarkable job stitching images together.  Most of my panoramas have been handheld, which makes the performance of MS-ICE all the more impressive.  I have shot a few panoramas using a tripod but without a nodal point (spherical) pan head, so that is what I was searching for online.  B&H Photo had a Manfrotto on sale for $280, marked down from $600, but their order desk was closing for the day and I did not want to be rushed making this decision so I did not order it.  They will reopen tomorrow, so I will think about it overnight and do some more research.

I got our old Webasto burner out of the front bay and found the label.  It is, indeed, a DBW2010, specifically a DBW2010.75 with a 0.35 GPH nozzle rated at 45,000 BTU.  Linda recorded the details, including the serial number, and then helped me rewrap it in bubble wrap so I could put back in its storage pail.

Linda then went to Parker, Arizona with Butch and Fonda to check out the Safeway grocery store and look for some things at Walmart.  The Parker Safeway was supposed to carry Daiya vegan cheese products but they were nowhere to be found.  It appears that our closest source will be Whole Foods.  There are five of them in the greater Phoenix area but that is a two hour drive one way.

While the three amigos were gone I removed the cover from the Aqua-Hot in our coach and found its label.  Much to my relief it is also a Webasto DBW2010.75, 45,000 BTU.  It should also have a 0.35 GPH nozzle, and probably does, but I did not pull the burner out to check.  I noticed some soot on the final fuel filter inside the housing and in other places so that gave me something new to be concerned about.  I was pondering the situation when Jim and Barb and Roho came over to visit and we had a good long chat.  When they went back to their motorhome I put the cover back on the Aqua-Hot and put all of my tools away.

My plan for tomorrow is to turn the Aqua-Hot off, let it cool down, and pull the burner to check the nozzle.  It’s possible, though not likely, that I do not have the burner seated quite right and there’s a chance, though very small, that reinstalling it will fix, or least improve the performance.  My money (literally) is still on the blower bearings.  Hopefully it does not also need a new motor as everything on a Webasto is more expensive than seems reasonable. It’s another fine example of precision German engineering and manufacturing.

Even though I have quite a few e-mail addresses that I use to segregate electronic correspondence into manageable categories my inboxes still end up flooded with e-mails.  Very few of them are spam—we have good spam filtering on all of the accounts—but some of the highest volume inbound traffic is notifications of things like failed login attempts on WordPress websites.  Those e-mails do not get replies and often do not require any specific action on my part, but they sometimes obscure the presence of other e-mails that do require my attention.

Microsoft Outlook is able to deal with incoming (and outgoing) e-mails based on user-defined “rules” but I had never played with that feature until today.  I used the online help system to read about the whys and wherefores of e-mail rules and then tried creating some.  Once I understood what I was trying to accomplish it was mostly point and click to get it done, with a little typing thrown in.  What I ended up doing was creating sender/subject subfolders under the inbox of certain accounts and then creating a rule for each subfolder that directs incoming e-mails matching the criteria to the correct folder.  By keeping the sub folders under the inbox folder it will be clear to me that these are e-mails that I have received but not yet dealt with.

For dinner Linda made a cooked shredded Brussels’ Sprouts dish with tomatoes, dried cranberries, and pistachios and served it alongside the leftover Mexican rice with a glass of sangria.  Ole!  We agreed that both of these dishes were keepers and went well with the fruity wine.  The rest of the evening was quiet.  Linda read and played her online games while I finished up working on this post.  I finally went to bed and started reading the service and repair manuals for the Aqua-Hot system and the Webasto burner.  According to the long-term weather forecast tonight should be our last night with an overnight low temperature below freezing.

 

A few of the vendors at Desert Gardens, Quartzsite, AZ.

A few of the vendors at Desert Gardens, Quartzsite, AZ.

2015/01/03 (S) Hammer Stahl

I got up at 6:30 AM today.  I had been awake for a while before that and had some things I needed/wanted to do on my computer.  These were quiet tasks that I could do in the front of the coach, with the heat turned up, without disturbing Linda.

I always check my e-mail first.  There was a group message from Hillary at RVillage to all of the Ambassadors regarding a new feature they will be rolling out soon and seeking our assistance.  I mentioned this to Linda when she got up and we watched the two YouTube videos.  We did not have time today but will work on it tomorrow in advance of a 5 PM (4 PM PST) web meeting.

My first project today was updating the spreadsheet I maintain for our FMCA Freethinkers Chapter, which I started working on last night.  The chapter treasurer maintains our checking account but as the secretary I maintain the records including the roster and who has paid their dues for what years.  Because I have all of those details I also generate the quarterly and annual financial statements.  I entered the information for dues payments that had been received between November 1 and December 31.  I then added the five worksheets for 2015 (four quarters and year), which tie together and link back to the 2014 statement, and updated the cumulative financial statement.

Linda got up so I put my work aside to make coffee while she made breakfast.  We had a few bananas that were ripe so she made green smoothies for breakfast.  We happen to like kale but if we didn’t, green smoothies would be an excellent way to get our daily dose along with several other healthy ingredients.

We talked about visiting the market area today and decided to go later when it was a bit warmer.  The temperature a 9AM was still only 40 degrees F so Linda bundled up and went for her morning walk while I continued to work on my spreadsheet.

Once I finished the spreadsheet I worked outside for a bit.  I removed the cover from the burner end of the Aqua-Hot while it was running to check for an exhaust leak (sight, smell, touch) but I could not detect one.  When the cycle finished I turned the burner off.  My plan was to let the unit cool off and then remove the burner to check the nozzle size and do a general inspection of the combustion chamber and visible parts, but that did not happen today.

What I did instead was return to my computer and start putting Webasto repair parts in my shopping cart on the Sure Marine Service website.  The bearings on the installed burner are definitely whining and need to be replaced.  They are supposed to be replaced regularly anyway, so I put two sets in the cart.  It is very likely that they are causing the motor to run slow which means insufficient combustion air, and possibly lower fuel pressure, leading to the dark smoky exhaust.  I also put a fuel solenoid valve in the cart.  There is a good chance that the valve and/or the solenoid are not working on the other burner.  There’s also a chance that the ignition coil has failed, but the solenoid valve costs 1/2 as much as the coil, so I’m hoping it’s the valve.  I got the order submitted with UPS ground shipping and used PayPal to make the payment.

Once I completed the SMS order I loaded the B&H Photo app onto my iPad and spent quite a bit of time going between their website and the Sony online store trying to figure out if I should order a panoramic tripod head and/or new camera, possibly with a lens and flash unit.  Sony has the Alpha 99 FF body marked down from $2,800 to $1,900 with the vertical grip and an extra battery thrown into the deal, an additional $500+ value.  They will also bundle in the SAM 28-75mm f/2.8 lens for $400.  The lens by itself is normally $900, so that’s another $500 savings.

So for $2,500 I could get $4,200 worth of Sony’s top-of-the-line “flagship” DSLR (DSLT, actually) equipment, except for one thing; it was all on back order with an ESTIMATED ship date of February 4, 2015.  That’s my birthday, so if it actually shipped on that date it would be quite the birthday present, but if it was delayed very much there would be the very real possibility of it arriving at our location in Q after we had left.  Not good.

So what about B&H Photo?  It turns out that they (claim to) have all of these pieces in stock and they are selling the body with the added pieces for the same price as Sony, but they are not offering the lens at the bundled price.  That was the deal breaker that saved me spending a lot of money today.  Besides, I have been waiting a long time for Sony to officially announce and the ship the new (rumored) flagship alpha a99-II with its 36MP FF 35mm sensor and long list of awesome features.  To decide now to by prior generation technology it would have to be a very attractive deal, much better than what I was seeing online.

I ended up ordering a Manfrotto Nodal Point Pro panoramic tripod mount from B&H.  It should be here by the end of the week.  When it arrives I think we will hike up to the top of “Q Mountain” and try to capture the true essence of Quartzsite in the winter, which is RVs from horizon to horizon.

We headed down to the market area on Kuehn Street with Butch and Fonda and walked around for a couple of hours in the Tyson Wells Show grounds north of Kuehn Street and west of Central Avenue (US-95).  This particular market area had really filled up with vendors in the last few days.  Linda bought a nice white apron and really nice Hammer Stahl 5.5″ Santoku knife.  She checked online when we got back and she paid about 55% of the MSRP on the HS website.  She bought it from Cutlery by LeClaire, which also has a website, and has it on sale for $20 more than the price on the HS website, marked down $20 from their “regular” price.  The point is, she got it for what appears to be a good price of $59 and it came in a nice box with a ceramic sharpener thrown into the deal.

We drove farther west on Kuehn Street and pulled into the Desert Gardens show grounds.  It was getting near sunset, so we did not stay long, but Linda and I walked enough of it to get a feeling for the place.  It was a “rougher” setup than Tyson Wells and many of the booths were selling large, rough rocks and gemstones.  The vendors also had a lot more equipment set up and were using it to process materials.  We’ll be back, probably more than once, and earlier in the day so we can spend more time.

When we got back to our motorcoaches Fonda came over and worked with Linda for a little while on their business records.  We then had a nice salad and some of the spicy bean and pasta soup (that Linda made the other day) with crackers and sangria.  I spent more time after dinner researching stuff on my iPad and working on this post.

We appear to be in one of the few places in the country that is not getting clobbered by bad weather. The temperature is not even supposed to drop below freezing overnight. It will still be cool tomorrow, however, and we did make specific plans before going to bed.

 

A view of "Q" Mountain from the Desert Gardens Show area.

A view of “Q” Mountain from the Desert Gardens Show area.

2015/01/04 (N) Our Village

We had vegan pancakes for breakfast which prompted me to suggest that Linda invent some recipes, even if they are interesting and successful variations on existing ones, and feed them to our grand-daughter.  Linda could put them on our website using the WP Ultimate Recipe plug-in and, if they met with her approval, name they after “Bitty” (youngest grand-daughter’s latest nickname, although I think I will always prefer “Schmoo”).  Perhaps Pancakes Madeline; Sautéed greens a la Madeline; Pasta Madeline; or Madeline’s vegan mac and cheese.  Being retired gives me a lot of time to think.

Joe’s brother, Jim L., finally returned from Nevada today and was able to get the park model trailer unlocked.  Barb has been wanting to get in and clean it since she and Jim (different Jim) arrived.  Barb is a keep busy kind of gal.  She is responsible for maintaining the apartment and laundry room while she is here and told Connie she would also do some deep cleaning on their house trailer, so it’s been bugging her that she could not get in to do it.  As for my part, all I did was lock the door on the trailer the way Connie asked me to.  Barb and Jim (husband) had lots of keys but could not get any of them to work.

 

Today was shower day.  This is always more of a production than we would like because we keep the cats’ litter tray in the shower.  Most of the time that works really well—it is out of the way and contains any mess they might make—but it is inconvenient when we want to use the shower for its intended purpose.  Besides pulling the tray out into the hall by the bathroom door we have to clean up any stray litter in the shower to make sure it does not end up in the gray water waste tank.  Litter tray or not we still have to spray the shower walls when we are done, squeegee off the glass door, let everything dry, and then reassemble it as a giant cat litter box.  But it works and it’s one of the compromises we willingly make to live with our cats in so few square feet.

 

Once I was dressed I went outside to chat with Jim L. (Joe’s brother) and we discussed the possibility of upgrading the electrical service at our site to “50 Amp” (240VAC, 50A, 4-wire, the equivalent of a 120VAC, 100A residential service).  It’s not an issue for us right now as the cool weather has us burning diesel fuel to make space heat, but once the weather turns warm we may need our air-conditioners.  We have three but can only run one on a “30A” service and still have enough power to run other things.  A 30A service is just what it says; 30A of current at 120VAC.  A “50A” RV service is slightly more than three times that amount of power.

 

The electrical hookups here are very interesting.  Perhaps all RV park power pedestals work the same way, but I have never looked inside one so I don’t know.  The meter is at the top and the area below it has a top-hinged cover.  Under the cover are three panels about 3″ wide and 15″ tall.  The panels have an outlet towards the bottom and a circuit breaker near the midpoint.  Behind the panels are busses for the hot, neutral and ground with male blade connectors.  The panels have female blade connectors that engage their male counterparts when the panel is slipped and then hinged into place.  It is secured with a single screw.  If Jim L. can find a 50A panel all we will have to do is unscrew and remove the 30A panel and plug in the new one, once we verify that 240 VAC (L1& L2) are present in the box and wired to the distribution busses.

 

Instead of her usual morning walk Linda setup her laptop on the dinette table and worked on accounting and tax issues for Butch and Fonda.  I set my laptop there as well to work on the roster for our FMCA Freethinkers Chapter and Jasper got in between us, so we had a nice, cozy computing session.  When I placed my order with B&H Photo yesterday I checked a box to receive shipping status information via TXT message.  I got one this morning letting me know that my package had shipped from NYC.  Cool.

 

With accounting chores done for now Linda prepared vegan hot dogs with mustard, onion, and relish for lunch.  She then went for a long walk while I stayed at the coach and worked with a new feature on the RVillage website.  I was posting a lot of suggestions to the topic thread on the Ambassador forum and got a phone call from Curtis, the founder/CEO of RVillage.   We had a long chat and I was still on the phone with him when Linda got back.  I worked with the website some more and at 5:00 PM we connected to an Ambassador meeting using GoToMeeting on my computer.  This is a very exciting new feature and I think RVillagers and RV-related businesses are really going to like it once they know about it and see how it works.

 

Linda made mock (vegan) stroganoff for dinner.  She normally uses Basmati but the only rice she had enough of was Texmati so she used that.  Although I did not care for the texture of the Texmati in this dish (a bit crunchy), the taste was still very good.  This dish requires real cooking, which means it makes a real mess.  By the time everything was cleaned up and put away it was 8 PM and we were both tired.  I continued to research engine and transmission gauges while Linda read and played word games.  I also revisited the SonyAlphaRumors website but there was absolutely NO new information on the a99-II.  I went to bed wondering if this camera will ever actually exist.  Based on the comments I see online I am not the only one wondering if this camera will ever be a reality.

One of the hundreds of vendors at the Tyson Wells market area in Q.

One of the hundreds of vendors at the Tyson Wells market area in Q.

 

2015/01/05 (M) VSWR 1.0

Yesterday we finished up the coffees we have been using since we left Michigan at the end of November so this morning I had to open new bags and transfer the contents from their vacuum sealed bags to our metal storage canisters.  I had Teeko’s roast Ethiopian Yirgacheffe regular and decaffeinated separately, so I opened 1/2 pound bags of each.  I also opened a 1/2 pound bag of our special Sweet Seattle Dreams, which is 1/2 Sweet Dreams (decaf) and 1/2 Seattle Blend (regular).  I then made a pot of Ethiopian Yirgacheffe 1/2-n-1/2 while Linda prepared our granola with fresh bananas and fresh blueberries.

 

Linda went for her morning walk while I continued to do online research regarding the enigma known as the Sony a99-II DSLT camera and the supposedly discontinued, but apparently still very much available, Sony alpha a99.  If I did not already have a nice assortment of compatible Minolta A-mount lenses and flash equipment I think I would stop wasting my time with Sony cameras.  But I do, and so I continue to wait and be frustrated along with thousands of other “enthusiast” (sub-professional) photographers.  Because Sony builds the image stabilization (anti-shake) feature into the alpha bodies instead of the A-mount lenses the feature is available even with older Minolta lenses and the new lenses are slightly less complicated and less expensive than the Nikon and Canon lenses, which have the image stabilization built into each lens.  I think this was one of Sony’s best innovations.

 

I also continued to look at automotive gauges and sending units and decided to call Bill Gerrie (in Ontario, Canada) to follow up on his reply to an e-mail I sent a few days ago.  We had a great chat and he was able to clarify some things and add quite a bit of specificity to his written reply.  As a result I have a pretty good idea of what I am looking for; now it’s just a matter of finding it and deciding to place the order.

 

I was starting to work at my computer when Linda returned from her walk.  She eventually fixed a couple of vegan hot dogs wrapped up in tortillas with mustard, onions, and relish.   As I was finishing my meal I got a call from Gary Hatt at BCM.  He recently acquired an Eagle bus conversion and had some questions about the air-conditioners and the Aqua-Hot.  He plans to be in Quartzsite next to week and we are looking forward to finally meeting in person since I have been writing articles for the magazine for almost two years.

 

Linda has been having a problem with the brightness (or lack thereof) of the touch screen on her 19 month old Windows 8.1 Samsung laptop.  It will go very dim for no apparent reason and cannot be adjusted.  There was a driver update available for the Intel HD Graphics processor so we downloaded it, installed it, and re-started her computer.  The screen was now bright, which was more useful than dim, but still not adjustable.  That could be a coincidence or a fix, we will have to wait and see.  Even though it was working (for now) I drove to the local Family Dollar and bought an HDMI cable and some lightly carbonated water.  (The water had nothing to do with Linda’s laptop computer display, we were just low on sparkling water.)  The cable will allow us to connect her computer to one of our two flat panel LCD (LED) TV/monitors if needed.  (We did that after dinner and it worked, mirroring the built-in display to the monitor and setting the resolution to match the monitor’s 1900x1080p native mode.  But it also caused the built-in monitor to dim, although not as much as before.  When we turned off the monitor and unplugged it the built-in display did not return to full brightness.)

 

Mid-afternoon I saw Butch working on his Tarheel screwdriver antenna so I inquired as to what he was doing.  He had connected his MFJ VSWR meter to it through a six foot length of coax.  He had also unplugged the control harness for the tuning motor and rigged up a temporary switch to extend and retract the antenna.  He had done this because he was getting meter readings when connected through the installed coax that indicated the antenna was not resonant at any frequency or that the meter was not working correctly.  I climbed up on his ladder to have a look and saw VSWRs that were often greater than 31:1, and never fell below 10:1, with complex impedances that were rarely 50 ohms and with both resistance and reactance values that were all over the place.  Clearly something was not right.  It was not his installed coax and I was fairly certain I was not his meter, which I had used back at their house to check the VSWR on his CB and 2m ham antennas.

 

I climbed onto the roof of their bus so it would be easier to reach things and I could work sitting down.  We tried adding a ground strap as a counterpoise but it didn’t help.  Butch then grounded the strap to the chassis at the motor but that did not help either.  Our concern was that the antenna was not sufficiently bonded (grounded) to the roof but nothing we tried made any difference.  I decided to set the antenna to its shortest length (highest operating frequency), set the meter to a lower frequency, and then slowly lengthen the antenna, thereby lowering the operating frequency, while looking for some sort of response on the meter.

 

I got no change on the meter and finally realized that the antenna (via the meter) was behaving as though it was not grounded.  I noticed what looked like a thick washer between the SO-239 antenna connector and the base mounting plate of the antenna.  The mounting plate is the ground reference for the antenna and is connected to the base of the antenna through a coil of insulated wire (an inductor) known as a base loading coil.  The spacer was a plastic insulator that was, indeed, preventing the case of the SO-239 antenna socket from making contact with the mounting plate.  As a result the antenna was not grounded through the coax cable shield, preventing the meter from obtaining meaningful readings.

 

We removed the antenna connector, removed the insulated spacer, reassembled the connector to the antenna, reattached the coax and meter, and took additional measurements.  This time we got excellent readings that made very good sense.  We checked the upper bound, lower bound, and the midpoint of most of the high frequency (HF) ham bands and were always able to obtain VSWRs of 1.3:1 or less, which was excellent.  Butch had been considering redoing the mounting of the large motorized fold-over base so it was a good thing we figured this out as it saved him a lot of unnecessary work.  If I can solve one problem without creating others I figure it’s a good day.  BTW:  VSWR stands for Voltage Standing Wave Ratio and 1.0 is not a beta version, it is shorthand for a ratio of one-to-one (1:1), which is the best SWR you can have.  Anything below 1.5:1 is considered excellent, below 2.0:1 good, and below 3.0:1 usable if that’s the best you can do.

 

Chayote is a fruit that is a member of the squash family and is related to other gourds such as melons and cucumbers.  Linda bought one last week when we went to Albertson’s grocery store in Blythe, California and decided to prepare it for dinner tonight.  She sliced it into long thin broad strips and sautéed them with onions, oregano, salt, and pepper.  She served it alongside the leftover mock (vegan) stroganoff with a glass of sangria.  Our wine friends can cringe all they want; we find the Vella and Franzia boxed wines generally agreeable and the sangrias go surprisingly well with a variety of dishes.  And it has me drinking red wine, so it’s healthy too!

 

We lost our WiFi connection this evening.  Not sure why.  The wireless gateway still shows up in the WFR list but won’t associate with the WFR.  Butch had the same problem at the same time so something obviously changed.  We will ask Barb to open the trailer tomorrow, or get Jim to do it if she is not comfortable, so we can reset the gateway.  Hopefully that will do the trick.

The sunsets in Quartzsite are amazing almost every night.  This shot was taken from our campsite in Q.

The sunsets in Quartzsite are amazing almost every night. This shot was taken from our campsite in Q.

 

2015/01/06 (T) You’ve Got Mail (Maybe)

 

Our mail situation here is interesting.  Remember that, per our Jamaican tour guide, we do not have problems, only situations, and situations are easier to deal with if I regard them as interesting rather than annoying.  With regards to receiving mail, the “situation” is as follows.  Although every structure in town has a street address—necessary for police, fire, EMS, trash collection, and other municipal services—the Quartzsite post office does not deliver mail to said locations.  They have an annex building on the northeast side of town that is nothing but P. O. boxes and all of the locals, and a lot of seasonal residents (including Joe and Connie, who own the property where we are staying) have a P. O. Box.

 

Where things get interesting is that the main post office and the street addresses are associated with one ZIP code but the P. O. boxes have a different ZIP code.  If something is coming to us via UPS or FEDEX we have to use the street address and associated ZIP code, but if it is being mailed to us USPS we have to use the P. O. Box number and associated ZIP code, or have it sent c/o General Delivery using the main ZIP code.  To confuse matters further, Joe and Connie had to return to Nevada because of Joe’s health and are having their Quartzsite mail forwarded back to their home, so we cannot have mail sent to us “care of” them as we originally planned as it just gets forwarded to Nevada.  Outbound mail does not appear to be a problem, but then why would it be?

 

The other situation that developed yesterday was that our WiFiRanger Mobile Ti disconnected from Joe and Connie’s WiFi (DSL) gateway and would not reconnect.  The WFR is telling us that the WPA password may be incorrect, but that is unlikely as we have been using it since we arrived last month, as have Butch and Fonda who also lost their connection yesterday and could not reestablish it.  The evidence suggests that the gateway needs to be reset.  Why?  Who knows?  DSL gremlins perhaps.  Or mischievous Internet fairies.  Or a problem with the local DSL service?  Or perhaps Butch keyed up his 600 Watt linear HF ham radio amplifier and blew out every wireless DSL router within a quarter mile?  Whatever the cause, once we can get Barb or (brother) Jim to open the trailer we will power cycle the gateway and see if that restores our ability to connect to it.

 

In the meantime, in order to get online last night and again this morning, we turned on our Verizon MiFi.  The Verizon signal here is strong and steady, and the data rate is much faster than the DSL/WiFi connection, but we only have a 4 GB data plan so we tend to use WiFi when available.  It is not always available, of course, especially while traveling (and especially if we are boondocking at Wally World or other such locations) and when it is available it is not always reliable or is so slow as to be useless.  This can be the situation, for instance, at larger RV rallies and even some RV parks.

 

So we logged into our Verizon Wireless account, looked at our current plan, and saw that for a mere $10 more per month we could increase our data plan from 4 GB to 10 GB.  The cost for exceeding your monthly data plan limit is $15/GB, so the extra $10/month was a no-brainer.  And VZW made it soooo easy to change our plan (once we were logged in); just click the data plan we want, review changes to our account, and click “Apply Changes.”  Done; they have our money and we have more data allocation.  Interestingly, they upped our data allocation immediately for the current billing cycle, which is Dec 20 – Jan 19, and added the $10 to the bill we will receive for that cycle.  No pro-rating going on here, but then we can use the whole 10 GB if we want/need to.

 

Interestingly the cost to go from 10 GB to 15 GB was an additional $20/month, so the 10 GB plan seems to be a sweet spot after which you pay a premium for additional access.  On the one hand Verizon wants to sell you data bandwidth but on the other hand there is a finite amount of data they can move through their network, so if you want to use a larger chunk of their capacity it figures that it would come with premium pricing.

 

Until a few months ago Millenicom was reselling 20 GB MiFi plans (on Verizon’s network) for $70.  It was the best deal around; a sufficient amount of data for the same price we were paying Verizon for only 4 GB.  Kind of unfair, when I think about it.  Well, Verizon decided to stop selling bulk capacity to Millenicom (and other MVNAs?), took all of the accounts in-house, and Millenicom went out of business.  Not really a big surprise when you think about it.  Verizon also notified those customers (as I understand the situation) of their “options” which were not, apparently, as attractive as the deal they had with Millenicom.  Not really a big surprise when you think about it.

 

Anyway, we will see how we do with 10 GB/month while we are on the road.  We can change back to our 4GB plan when we get home, but I doubt that we will, and we can increase it to 15, 20, or even more GB per billing cycle if we need to, but that is unlikely.  We have an AT&T landline at home with DSL service that provides an “always on” Internet connection (when it works).  It has a 150 GB/month data allowance and allows us to monitor and control our whole house generator and WiFi thermostat.  We have discussed adding a security system and a personal weather station linked in to Weather Underground’s Wundermap when we get home.  I don’t think our DSL connection is fast enough, however, that we could use 150 GB in a month if we tried.

 

Linda went for her morning walk and I made a quick run to Barry’s Breads.  Barry is a really nice older gentleman who has a small bakery stand on the north side of Kuehn Street east of Central Avenue.  Just behind the stand, however, is a larger trailer in which he bakes all of his products.  Those products include breads, rolls, savory items, and sweet goods.  Most of his products use butter, cream cheese, cheddar cheese, or ranch dressing, but his Basic Bread is just that, flour, water, sugar, salt, and yeast.  I have had some difficulty figuring out what time of day to stop by but this morning he finally had loaves of bread, and some hamburger buns made from the same recipe, so I bought a loaf and a pack of four buns.

 

When I got back I started working on another article for Bus Conversion Magazine.  A little over a year ago I installed an RV-Critter Guard to seal around the shorepower cord and water hose where they enter the utility bay through the floor.  I took a few pictures during the installation and have had the article on my “future” list ever since.  By the time Linda got back from her walk I had the article mostly finished and was starting to look at the photographs.

 

She had stopped at the Salvation Army store, which was open, to use their facilities and ended up buying a grocery bag full of clothes for $1.  Not $1/item, $1 for the entire bag.  Most of the items were tagged with color codes indicating prices of one or more dollars each but they had too much inventory and needed to move some product.  They told Linda that when that happens they have their $1 bag sale.  Deal.  She called Butch and Fonda to let them know and I think they headed there before going to check the post office box and then stop at the post office if needed.

 

Linda cooked a couple of our Boca vegan mock hamburger patties and served them with fresh sliced onion, lettuce, and pickles on two of the buns I had just purchased.  Not an entirely WFPB meal, but very few of our meals are.  Still, we try to get as much plant-based whole foods as we can every day.

 

Linda went for a second walk after lunch and headed down Central Avenue towards the Kuehn Street markets.  She is so fond of her 5.5″ Hammer Stahl Santoku knife that she wanted to buy the 3.5″ paring knife if Cutlery by LeClaire had it for sale as an individual item.

 

While Linda was gone I finished working on the photos for my RV-Critter Guard article.  When she returned from her walk she had both the Hammer Stahl 3.5″ Paring Knife AND the 3.0″ Birdsbeak Paring Knife.  As we learned the other day from an Alton Brown video paring is actually a technique in which food is held in one hand and a knife in the other; no cutting board is involved.  Paring knives are generally smaller with a shorter blade and most of the weight is in the handle, allowing very fine control of the cutting edge and tip.

 

The Birdsbeak is a particularly interesting and unusual knife.  The bottom/cutting edge is slightly concave rather than convex like the classic chef knife.  The bottom edge joins the top edge in a point with a shape that resembles certain types of curved bird beaks.  In use, the knife is often held stationary and the food is pressed or turned into it, such as decorative peeling, pitting of fruit, or slicing strawberries.  Linda is often reluctant to spend money on herself so I think it’s nice that she found something she wanted and made the decision to buy it.  Like any high quality tool it will make the work it is designed to do easier and more enjoyable.

 

While I was uploading my article to our Dropbox Linda went outside to sit.  Barb wandered over and I mentioned that the DSL wireless Internet gateway had quit working.  She let me in the trailer where I found it sitting on the dining room table.  I powered it off, waited 60 seconds, and powered it back on.  All of the status lights came back on in the expected sequence and I was once again able to connect our WiFiRanger Mobile Ti to it.  We ended up standing by their Country Coach Intrigue motorhome and having a long chat.

 

Butch and Fonda were gone for most of the afternoon so we only got to chat for a little while when they returned before the sun dropped behind the southwestern mountains and the temperature dropped along with it.  Linda and I talked about going out to dinner, which we have only done once since we got here, but she remembered that we had a FedEx package scheduled for delivery today and that it might arrive as late as 8 PM.  So we had leftover soup with crackers and sangria.  This was the third and final meal we got out of this pot of soup and it was good to the last drop.  It was a packaged mix but Linda thinks she can recreate it; getting the spices right will be the tricky part.

 

After dinner I read DSLR reviews on the Digital Photography Reviews website and continued to look at gauges and sending units for the bus.  Around 8:30 PM I was having trouble staying awake but by 9 PM I had gotten my second wind and decided to write another short article for BCM.  This one was on the failure of Butch and Fonda’s main engine air-compressor on the drive down, how he dealt with it on the road, and eventually ended up installing a rebuilt one here at our campsite in Quartzsite.  I had the article written by 11 PM and decided to work on the photos tomorrow.

Sunset envelopes our coach as Linda prepares dinner.

Sunset envelopes our coach as Linda prepares dinner.

 

2015/01/07 (W) Catch 22

 

My main pair of reading glasses broke yesterday; not the lenses or the frame, but one of the nose pads.  Well, not the actual pad, but the small plate and mounting loop, specifically the mounting loop.  I was cleaning them and the whole assembly fell out.  The loop was split and had opened up.  The loop was a very small and delicate piece of ductile metal so I squeezed it back into a circle.  I removed the very tiny retaining screw, reinserted the mounting loop, and put the screw back in.  I was able to do this using only the tools available on my Leatherman.  The repair did not hold and it fell out again last night.  This time a piece of the loop broke off so the only repair will be a new mounting pad if I can find one.  There is a Wal-Mart in Parker that probably has an optical shop but I don’t know how universal this mounting system is.

 

I checked the level of the floor and counter in the kitchen last night and the coach appears to have settled slightly on the driver side.  Not a lot, but enough that I can feel it and it registers on the level.  I generally have to start the main engine and build up full air pressure in order to level the coach but I thought today would be a good day to finally pull the portable air compressor out of the car and see if the leveling system will work without the main engine running.  As it turned out that did not happen today because we ended up driving to Parker, Arizona.

 

Our destination in Parker was the Wal-Mart.  The store did not have an optical department but we found an eyeglass repair kit in the pharmacy area with a pair of screw-in pads and a pair of snap-in pads.  They also had a repair kit with a tiny screwdriver, spare screws, and other parts.  Between the two kits I was able to install a new pad in the car to replace the broken one.  That saved us a trip the optical shop in town.

 

Parker sits on the Arizona side of the Colorado River which is the boundary with California.  We decided to drive across and then take CA-62 over to US-95, follow it south along the River back down to Blythe, and then take I-10 back to Quartzsite.  Butch called while we were in Parker to let us know that there was a Farmer’s market at Desert Gardens.  It operates on Wednesdays from 8 AM to noon so we did not make it back in time but resolved to go in future weeks.

 

I worked on my “roadside repair” article for BCM while Linda went for a walk.  Jim and Barb had gone to Blythe to buy a new faucet and Jim L. stopped by and helped Jim B. install it.  They borrowed a caulk gun from us (we carry two in the bay) but had to go buy caulk.  UPS showed up with yet another package for us, after which we had a long conversation about the inadequacies (incompetence) of the U. S. Post Office in Quartzsite.  (The UPS driver told me that both UPS and FedEx have extra drivers and trucks delivering into Quartzsite during the peak season.  What a novel idea.)

 

Back to the post office.  We are waiting for a shipment of two bottles of water hardness test strips that we ordered through Amazon but were shipped via USPS by a swimming pool supply company in Elkhart, Indiana.  I gave them the P. O. Box here in Q since the post office does not deliver mail to street addresses and it appears that they will likely get returned to the sender rather than delivered to us.  The root cause of the problem (and it is a problem) is that Joe and Connie are having their mail forwarded to their home in Nevada.  If their names are not on the mail the post office won’t put it in the box, but if their names are on the mail it still does not get put in the box, it gets sent to Nevada.  So as of now the box is sitting there but cannot be used; a genuine “catch 22.”

 

Fine, we will just use General Delivery.  The problem with that (and it is a problem) is that you can only pick up the GD Mail at the Quartzsite post office between 11AM and 1 PM, and there are untold numbers of people trying to do the same thing.  That means ridiculously long lines and ridiculously long waits.  Considering that the influx of seasonal “residents” to Quartzsite has been going on for over 30 years the postal “service” has had ample time to figure out how to handle the situation.  I mean, Amazon practically runs its holiday operations with seasonal employees, many of whom are RVers.  Gee, I wonder if there are any RVers around Quartzsite this time of year.  While the post office is trying to figure out how to not deliver our mail we have two more UPS shipments scheduled to arrive on Friday.

 

Linda made a zoodle dish for dinner.  She used her SpiraLife to turn a zucchini into long thin strips which she cut into 6″ lengths and then used like spaghetti in the dish.  The other ingredients were onions, garlic, mushrooms, asparagus, and green beans.  Everything got sautéed in a pan with a little olive oil, salt, and pepper.  We had a glass of Lamb’s Valley Organic Sweet White wine and it was a lovely meal.

 

After dinner I put the finishing touches on my BCM air-compressor repair article and e-mailed it to Butch to proof-read.  The only thing worse than writing an article that makes me look stupid is writing one that makes someone else look stupid, especially a friend.

 

I had an e-mail from Gary, the publisher of BCM, letting me know that the December 2014 issue was finally available online.  I downloaded both the SD and the HD versions.  I then clipped the cover from the SD version, pasted it into MS Paint, and saved it as a JPEG file.  I opened it in Faststone Image Viewer, resized it to a thumbnail, and sharpened it.  I then edited the BCM page on our website, adding the thumbnail image, the title of my article, and a brief description.  I have a similar entry on that page for every issue in which I gave had an article, starting with the February 2013 issue. The December 2014 article was my 14th in 23 months.

The last glow of this sunset reflects off the passenger side of our motorcoach in Quartzsite, AZ.

The last glow of this sunset reflects off the passenger side of our motorcoach in Quartzsite, AZ.

 

2014/11/10-16 Even More Bus Work

2014/11/10 (M) New Heights

We rarely set wake up alarms anymore, one of the major perks of retirement, but ‘rarely’ does not mean never so this morning my alarm went off at 5:05 AM.  I grabbed a quick shower, got dressed, and got busy pulling everything together for the trip to Twelve Mile, Indiana.  I had hoped to be on the road by 6 AM but did not quite make it.  Linda left at 6:15 AM for a 7:30 AM medical appointment and I had the car packed by 6:30 AM and pulled out shortly after that.

The drive always takes me about five hours including stops.  Butch called me around 10 AM to let me know they were in Logansport and would not make it back to the house until mid-afternoon.  I was going to stop in Rochester anyway to buy groceries so I had lunch first and then took my time shopping.  From Rochester I took IN-25 south and stopped in Fulton to buy fuel.  The street I normally turn on is Aitken and the filling station was at the intersection with IN-25 so I headed east to Meridian Street and then south to IN-16 and finally east to Twelve Mile.

New ride height linkage (L) with ball ends.  Old linkage (R) with rubber ends.

New ride height linkage (L) with ball ends. Old linkage (R) with rubber ends.

I pulled up in front of the bus at 12:30 PM and unloaded all of the groceries and bus parts from the car and put them in the bus.  I changed into my work clothes and started working on inside projects.  First up was resetting the clocks since the switch from EDT to EST occurred while I was away.  I then emptied the cabinet above the refrigerator, which is currently used to store cleaning supplies, in preparation for installing an under cabinet florescent light fixture against the ceiling.  I was investigating the details of that little project when Butch and Fonda got home.  With the house now unlocked I finished unloading my car and moved my clothes and technology into the guest bedroom, which is where I stay when I am here working on buses.

Butch had fabricated one of my ride height linkages while I was away.  He made a second one and then I gathered up tools and my camera to install them while he finished the last one.  Fonda found a large sheet of corrugated plastic that made it much easier to slide under the bus to work.  The front one was easy to install, just as it had been easier to remove.  The rear ones were even more difficult to install than they were to remove.  I got the rear protection shields back on with Fonda’s help.  Some jobs just require more than two hands.

New ride height linkage ball end and mounting bolt.  Old linkage end visible upper right.

New ride height linkage ball end and mounting bolt. Old linkage end visible upper right.

Bill Tharpe showed up to help Butch work on Brittiny’s car.  Butch and Bill had retrieved it a couple of days ago with a car hauler trailer when it quit running.  It was leaking coolant and apparently needed a new intake manifold gasket.  Bill spent most of his time disassembling the top of the engine so he can eventually remove the manifold.

Although I bought fresh salad greens on the drive down it ended up being a long day so I prepared a Simply Asia Mushroom Noodle Soup Bowl for dinner along with a few grapes.  Linda called at 8:30 PM and we chatted about her audiology and ENT appointments this morning.  The audiologist said her hearing in her ‘good’ ear was essentially unchanged from four years ago, which was good news, and she had a great visit with Dr. Siedman.  I chatted briefly with Butch about the fair weather ‘to do’ list for tomorrow and then we all turned in for the evening.

2014/11/11 (T) Code 23

I was up at 7 AM and in my coach by 7:30 having a simple, but yummy, breakfast of orange juice and homemade granola with unsweetened soy milk.  With all of the projects I have going on I have very little space at the moment to prepare food or sit and eat so I decided to forego making coffee and walked across the street to Small Town Brew to get some.  Lisa (the shop owner) was there so we had a nice chat.

New ride height linkage installed on front axle and leveling valve.

New ride height linkage installed on front axle and leveling valve.

The weather forecast indicated that the best part of the day was going to be the morning with the high temperature of 54 degrees F at noon and then falling steadily with a rapidly increasing chance of rain.  I had two outside tasks to accomplish on my bus today so I wanted to get them done in the morning if possible.  My first task, however, was to attach the stinger (or whip, the long slender flexible piece at the top of an amateur radio antenna) to the base screwdriver portion of Butch’s mobile HF ham antenna.  I was able to do this from his ladder and did not have to get up on the roof.

While I worked on the antenna Butch prepped their new motion-sensing patio light.  He installed it over the entrance door to their bus with Fonda’s help.  With his assistance I removed the new fan belt from my engine, removed the two old air-conditioning compressor belts, and installed the two new a-c belts.  It was obvious from the extra slack in the inside belt that the a-c compressor was out of alignment with the pulley on the engine.  Butch suggested that we take the new belts off rather than ruin them and put the old ones back on until we can align the compressor.  That made sense to me, so that’s what we did, finally putting the new fan belt back on.

The drive side rear ride height linkage was not easy to get to with the dual drive tires on the axle.

The drive side rear ride height linkage was not easy to get to with the dual drive tires on the axle.

In the process of changing the belts I tried to us the valve that either tightens the belts when the engine is running or retracts the belt tensioners when they need to be changed.  The retract position did not appear to work and after looking at how the valve was plumbed Butch and I were of the opinion that it may not be connected correctly.  The run/tighten position works as intended, extending the air-driven belt tensioners, but it would sure be nice to be able to turn the valve and have the belt tensioners retract as intended.  I’m going to have to find out more about this valve and re-plumb it if necessary.

Butch and Fonda had to take some time to move things out of their warehouse for someone who is coming by to purchase them.  While they did that I started working on the DDEC II code 23 (Fuel Temp Sensor Voltage High) problem.  I got the diagnostic procedure from Chuck over the weekend.  The first step was to remove the harness from the sensor, short out the two pins, turn on the ignition (but do not start the engine), and see what Active Codes the ECM (DDEC II) generates.  That sounded simple enough but unfortunately the Fuel Temperature Sensor is located on the right side of the fuel pump under the ECM and behind a coolant pipe.  The only way to get to it is to unbolt the ECM mounting plate from the block and lift it up, which it turn requires all of the harnesses to be unplugged from the ECM.  Again, simple enough in concept but more difficult in practice.  Once I could get to the sensor and disconnect the harness I had to figure out a way to jumper across the two sockets.  I ended up using two pieces of small solid wire inserted into the connector and then bent to give me something to connect the alligator clips to.  Fonda helped with all of this.  Again, it was more than a two-handed job.

Access to the passenger side rear ride height linkage was a little better, but not great.

Access to the passenger side rear ride height linkage was a little better, but not great.

I turned on the ignition and read the Active Codes on my ProLink and also had them flash on the Check Engine Light.  I was looking for a code 25 (everything is OK) or either a code 23 or a code 24.  What I got was both a code 23 (sensor signal and/or return wire open) and a code 24 (signal wire shorted to +5 VDC wire).  The diagnostic procedure has you check resistance between pins in either case, just different pins, so I checked both.  The readings I got did not make a lot of sense and I did not have time to pursue it further as the temperature had started dropping and it had started misting.  (I figured out later that the code 23 test requires the jumper to remain in place but I had done the code 24 test first, which required it to be removed, and not reinstalled it, so I did not do the Code 23 test correctly.)

By the time I got the ECM bolted back in place and all of the harnesses reconnected it was raining lightly and my tools were getting wet.  I got all of them put away and closed up all of the bays and decided to start the engine to make sure it would still run.  It started right up and I let it run on high idle for 25 minutes while I had a bite of lunch.  The test procedure called for clearing all codes before starting the engine and monitoring the CEL for 8 minutes, stopping the engine, and checking the historical codes.  I was clearly done working outside for the day so I did not get to do this at this time.

It was only mid-afternoon when I shut the engine off so I set to work installing the florescent light fixture in the cabinet above the refrigerator.  As with most projects this one seemed simple enough but took quite a while to do.  I was able to use an existing hole with wires running through it to snake two more wires through from the cabinet (where the fixture was going) to the adjacent cabinet to the right over the left corner of the kitchen counter.  That cabinet already had two 12 VDC light fixtures and I had previously identified the positive and negative supply wires.  What complicated matters was that the glue holding the carpet on the ceiling of the refrigerator cabinet had failed and the carpet was falling down.  The loose carpet also led to the discovery of other 12 VDC wiring hidden underneath it.  That, in turn, led to two things:  1) I had to make sure that when I mounted the new florescent fixture I did not screw through any of these wires, and 2) I had to figure out a way to keep the ceiling carpet up.

The sunset was amazing on November 10th.

The sunset was amazing on November 10th.

I taped the existing wires to the plywood ceiling so they would be in known locations.  I then used wood screws and fender washers to hold the carpet to the ceiling.  I added insulated spade lug connectors to the fixture wires and the supply wires and connected the other ends of the supply wires to the existing supply wires using special connectors designed for tapping into an existing wire without cutting it.  I would not use these for higher current applications but for a small florescent light fixture they are fine.  I attached the fixture to the ceiling with four short wood screws, installed the F13T5 bulb, turned the switch ON, and there was light!  I love it when that happens.

As long as I was working in this area I decided to reattach the incandescent fixture in the cabinet above the kitchen sink.  It was designed to be mounted with two screws but only one was in place.  Again, this turned out to be more work than it at first appeared.  The fixture is mounted to the inside of the upper cabinet face frame, not the ceiling, so there was no way to directly see what I was doing.  That meant mirrors and flashlights, and a blown fuse when my screwdriver shorted +12vdc to DC ground.  It turned out that the wiring was interfering with the mounting.  I eventually got it tucked up under the ceiling carpet and got the fixture mounted using two screws.  My documentation indicated that the upper kitchen cabinet lights were powered by wire #51.  I located that wire in the front DC distribution panel and pulled the 10 Amp fuse that protects it.  It was indeed open, which was good as it meant my documentation was correct and allowed me to find it on the first try.

The florescent light in the hallway ceiling cove quit working the last time I was here.  I removed the bulb, with some difficulty, to see what it was.  It was an F72T12 55 Watt (72″ length) with a single pin on each end.  I needed a 10 A blade fuse to replace the one I blew so I made a shopping list and headed off to Logansport to visit Walmart, O’Reilly’s Auto Parts, and Home Depot.  Since I was in town I called Linda as my cell phone does not work in Twelve Mile.  She wanted to know if I had shut off the outside water at home.  I had not, so she took photos of the valves/pipes in the utility room and e-mailed them to me.  I got a call from Butch while I was in town.  He needed a few machine screws so I picked those up.  When I got back to the house I checked the photos Linda had sent and then sent her a couple of replies which resulted in her calling the house to go through what had to be done.  She e-smiled me later that she had taken care of it.

I Replaced the F72T12 (with considerable difficulty) but it still did not work.  It was late, and dark, and I was tired, so finding and fixing the problem would have to wait until tomorrow.  Somewhere in there I had a tofu Italian sausage on a whole wheat hotdog bun with mustard and onions.  By the time I came in to the house Butch and Fonda had gone to bed.  I checked e-mail and logged in to RVillage ad saw that our “Vegan RVers (WFPB)” group was up to 100 members.  I worked on this post and then went nighty night.

2014/11/12 (W) Burrrr

The leading edge (cold front) of the polar vortex had passed through north central Indiana by the time we got up this morning.  There was a definite bite to the air, and it will get worse before it gets better, but I brought a selection of winter clothing that I can layer in various was to suit the conditions and the work that needs to be done.  All of my projects today were inside the bus or the house so I did not have to bundle up excessively.  Butch and Fonda spent a little time working on the privacy curtain system for the front of their coach but much of their time today was taken up with someone who bought a lot of metal shelving and storage racks from them.  He showed up sometime between 9 and 10 AM and brought a crew to disassemble the shelving and load everything into a trailer.  Butch had to use his forklift to help load some it.

The DDEC II ECM on our DD8V92TA with all of the harnesses unplugged.

The DDEC II ECM on our DD8V92TA with all of the harnesses unplugged.

I had cleared some space in the kitchen (of the bus) so I made coffee to go with breakfast.  That emptied out the last of three storage canisters, so I opened the three bags of custom roasted beans from Teeko’s and transferred them to the three containers.  After considering my project choices I decided to install the knob on the front TV cabinet door.  I spent a few minutes checking the installation details and dimensions of the Gaggenau halogen cooktop, which we would eventually like to replace with a built-in two-position induction cooktop if we can find one that fits the existing opening in the kitchen counter.  I had a note to get the GenSet model number for Martin Diesel so I looked that up in my documentation and found both the model and serial numbers.  I then turned my attention to the fluorescent light fixture in the hallway cove.

After studying the construction of the cove I realized that the front piece could be detached by removing seven (7) screws from underneath.  With the fascia removed I had great access to the F72T12 bulb.  I also discovered that there wasn’t an actual fixture there, just two ends to hold the bulb.  One was spring loaded and the other one was not.  The ballast was obviously somewhere else.  But where?

I vaguely recalled having seen a small metal box with wires coming out of it in the space under the bottom shelf of the pantry so I looked there and, sure enough, there it was.  It still had a label on it that was in good condition and indicated that it was a 13.2 VDC ballast for a single F72T12 fluorescent bulb.  Things were slowly starting to make sense.  There is an identical box in the back TV cabinet, with the same wires and connector but no label or markings, so I reasoned that it must power the fluorescent cove light in the bedroom.  That meant there were probably two more boxes somewhere for the two front fluorescent cove lights, although there might only be one as they are on the same switch.  Again, I vaguely recalled having seen these boxes in the bottom rear of the A-V cabinet behind the driver’s seat, so that’s where I looked first, and there they were.

Wire taps for joining a new wire to an existing wire.

Wire taps for joining a new wire to an existing wire.

It appeared that we had a bad ballast and that this would be an easy fix.  The label said the ballast was a Triad made by Magnetek in Huntington, Indiana and had the model number.  Cool.  I could drive over there and get one if I had to.  I went inside to use my iPad to search for sources of supply and found that Magnetek had divested itself of most of their product lines, including this one.  Their website gave the URLs of the various companies that acquired their product lines.  Universal Lighting picked up the DC ballast products so I tried their website but did not find one for an F72T12 bulb.  Ugh.  I searched some more and eventually found a Bodine (Philips) ballast electronic/inverter ballast that appeared to be exactly what I needed…for $98 plus tax and S$H.  Double ugh.

I would eventually like to convert most of the lighting in the coach to LEDs, so perhaps this was the time.  I found a kit with 52.5 feet of LED rope light (~10 LEDs/in) and power cords, end caps, and mounting clips to make up to 10 segments.  The description said the light pattern was 360 degrees and the illumination was 48-60 lumens per foot.  An FTC website indicated that a typical 40 W incandescent bulb puts out about 450 lumens and a 60 W bulb about 800 lumens.  Figuring conservatively at 50 lumens per foot a 10 foot length, folded back mid-point to make a five foot long light source, should give us at least 500 lumens which is plenty of light for this application.  The kit has enough materials to make four such lights and still have 12 feet to use somewhere else, such as around the inside of the face frame of the wardrobe closet in the bathroom.  I ordered it with 3-day shipping.  While I was at it I ordered an Everpure (SHURflo) ADC Full-timer bacteriostatic water filter cartridge with 2-day delivery through Amazon Prime.  I thought about ordering several, but figured I might find them cheaper in Quartzsite this winter.

There wasn’t anything else I could do on the fluorescent fixture so I decided to shorten the cable for the front OTA TV antenna and put an F-connector on the RF coax portion.  I borrowed Butches crimper with the hex jaws and opened the coax cable stripper I bought at Home Depot.  I then discovered that the RG-6 connectors I had did not fit the cable, which was smaller in diameter.  Without different connectors this would be another stalled project with my front TV unusable.  Butch told me there was a Radio Shack store inside McCord’s Hardware and Lumber so I made a shopping list and headed to Logansport.

New florescent light in cabinet above the refrigerator.

New florescent light in cabinet above the refrigerator.

Based on the connectors available at Radio Shack I determined that my cable was probably RG-59 so I got four crimp style F-connectors.  While I was in town I stopped at Home Depot for a GFCI outlet to replace the one in the bathroom, which keeps tripping.  I also spotted some packages of cover plate screws so I got one each of white, almond, and brown.  A quick stop at Walmart for some personal items and I was headed back to Twelve Mile.

When I got back Fonda was just starting to make their dinner so I went to my coach to fix a salad.  I had a large salad of power greens, fresh mushrooms, fresh strawberries, onion, peanuts, and dried cranberries with a raspberry walnut vinaigrette dressing and a small glass of Moscato wine.  I then worked on the F-connector.

It took a while, and a couple of test fits, but I eventually figured out how to strip the coax, folding back the braided shield while leaving the foil shield in place, and get the prepped cable fully inserted into the connector and crimped it.  I stripped the three control wires, secured the little bit of extra cable inside the cabinet, and then connected the coax and control wires to the back of the controller.  Twelve Mile is a long way from everywhere but I figured I would I would test my cable construction by trying to tune in a channel.  The TV was having trouble receiving channel, 16-1 HD until I moved the antenna from position 8 to position 6.  Position 8 is just to the driver side of the nose, so given how I was parked it was facing slightly east of south.  Position 6 was more ESE, and the signal was good except when a truck went by.

Tarheel HF screwdriver ham radio antenna on motorized lift mount.

Tarheel HF screwdriver ham radio antenna on motorized lift mount.

I checked with Butch and WNDU 16-1 HD turned out to be a South Bend station.  South bend is north and slightly west of Twelve Mile.  Hummm?  I swung the antenna around to position 14, 180 degrees from position 6 and roughly NW, and had an excellent signal there too (I don’t recall it being interrupted by passing vehicles).  Clearly the F-connector was on well enough to transmit a clean signal.  The only thing I can figure is that my antenna had an unobstructed view of a large house in direction 6 that provided a very usable signal that was blocked by large trucks passing by.  Either way, South Bend is over 60 miles away, so propagation must have been very good this evening.

That was enough for one day.  I gathered up my dirty dishes and camera and returned to the house.  Fonda was just loading the dishwasher so I added mine.  I chatted a while with Butch about the DDEC II code 23 diagnostic procedure and the game plan for tomorrow and then turned in to check e-mail and work on this post.

2014/11/13 (R) Thermal Underwear

I slept in this morning so I skipped making coffee and after my usual breakfast went across the street to Small Town Brew to get some.  I then got to work on one of Butch’s projects.  We kept busy today including, in spite of the cold, some outside work.  Thermal underwear helped keep me comfortable.  I went back to STB and got a second cup of coffee around 10:30 AM.

I spent the morning helping Butch and Fonda with the wire chases for the bedroom in their bus.  Each chase is a pair of boards joined at a right angle to make a horizontal bottom and a vertical side.  They will each be mounted using a pair of aluminum angles, one on the wall for the bottom and one on the ceiling for the brackets for side.  My first task was to drill holes in the aluminum angles approximately every 12 inches.  I then helped position them, drill the holes for the mounting screws, and attach them to the bus.

Testing the DD8V92 fuel temperature sensor.

Testing the DD8V92 fuel temperature sensor.

Fonda and I moved three large wooden tables from the warehouse to the now mostly empty ‘parts room.’  All three of us moved a couple of loaded metal shelving units and then Fonda and I put the wooden tables in place.  I plan to move my all of the stuff I have in the (unheated) warehouse to the (heated) parts room tomorrow.

I worked on some minor projects in my bus and had a tofu turkey sandwich with vegan mayonnaise, lettuce, and onions.  I disconnected/removed the ballast for the bedroom fluorescent cove light and used it to test the hallway fixture.  The light worked just fine which verified that it was a ballast problem and not a wiring problem.  I needed to know that before I went to the trouble of converting this fixture to LED rope lighting early next week.  I put the good ballast back in rear TV cabinet and kept working in there, starting with the installation of the knob for the TV cabinet door.

I shortened the control/coax cable for the TV and installed the crimp-style F-connector.  Unlike the front TV (which was on and receiving WNDU Ch-16 from South Bend over 60 miles away) the rear TV was not able to detect any signals at any antenna direction.  The OTA antenna for the rear TV is in the rear roof tray and the bus is backed into its parking spot, so it is more shielded from radio frequency waves than the front antenna.  The only direction that might be good is straight ahead, which is due south.  Unfortunately there are no TV towers in the direction for a long way.

Magnatek 13.2 VDC ballast for F72T12.

Magnatek 13.2 VDC ballast for F72T12.

Butch decided to install the plate heat exchanger in the bay just forward of where the Oasis Combi is installed and needed my assistance.  The plate heat exchanger will be used to tie the Combi to the OTR bus heating system (engine coolant loop).  We also discussed possible locations for the coolant circulating pump that he plans to plumb into the OTR heating lines once he determines which line is the supply and which one is the return.

I returned to my rear TV closet projects while Butch started compiling a shopping list.  After stabilizing the back piece of plywood inside the cabinet with a couple of screws I mounted the Pressure Pro Repeater to it using a couple of self-adhesive Velcro pads that came with it.  I then mounted the dual 12 VDC outlet directly below the ballast and installed a small cube relay just behind it using its built in mounting tab.  Tomorrow I plan to connect the outlets to the relay and supply it with 12 VDC to power the repeater.  I also plan to figure out a way to drive the relay from a 12 VDC source that comes on when the 12 VDC chassis battery switch is ‘ON.”  For now, though, I will connect the outlets to the NC (normally closed) contacts so that power will flow to the outlets when the relay coil is not energized.

I was pondering my next project when Fonda let me know that Butch would be ready to head to town shortly.  I was considering how I was going to enlarge the two small openings that allow air to flow from the grate in the rear TV cabinet through the upper parts of the center cabinet and into the driver side corner cabinet where the rear air-conditioner evaporator and blower are located.  At Butch’s suggestion I looked up the specifications on the Carrier air-conditioning units; 14,000 BTUs and 465 CFM air flow.  Requirements for supply and return grates?  At least equal to the square area of the evaporator coils.  The coils are roughly 9″ x 12″, as are most of the grates.  The two small openings in the side walls of the upper closet, however, are 3″ x 10″, not nearly big enough.  This is what happens when buses are converted to “look nice” instead of to “work correctly.”

Passenger side rear corner TV cabinet with ballast, dual 12V outlet, relay, AC outlets, and PressurePro TPMS repeater.

Passenger side rear corner TV cabinet with ballast, dual 12V outlet, relay, AC outlets, and PressurePro TPMS repeater.

I rode into Logansport with Butch where we stopped at O’Reilly’s Auto Parts, Aldi’s market, and Home Depot.  We ran into Bill Tharpe at O’Reilly’s and saw his car again at Home Depot.  When we got back Fonda was putting the finishing touches on their dinner so I made a salad and selected a can of Amy’s split pea soup and a can of Mandarin oranges.  I returned to my coach, cleaned up the kitchen area, and locked up for the night.  I spent a few minutes studying Butch’s MC-9 manual and finally found the diagram that identified the engine coolant supply and return lines.  That was a nice way to end the day so I retired to my room to work on this post and transfer photos from the last few days to my computer.

2014/11/14 (F) Arctic Oasis Grandma

I bought a dried fruit stolen last night at Aldi’s and had a few slices for breakfast this morning.  No animal products, of course, but a few less-than-desirable ingredients like HFCS.  Still, it was very tasty and not something Linda would be likely to buy at home.  I brewed a pot of coffee with a mix of the Cafe Europe Blend and Columbian Decaf beans from Teeko’s.  I had some with the stolen and drank the rest over the course of the morning.

Stacked plate heat exchanger to left of Magnum 4024 inverter/charger.

Stacked plate heat exchanger to left of Magnum 4024 inverter/charger.

Most of our work today was focused on trying to finish the installation of the ITR Oasis Combi in Butch and Fonda’s MCI MC-9 bus conversion, and much of that work was outdoors.  The temperature was around 20 degrees F when we got up this morning and never broke the freezing mark.  It was sunny most of the day, however, without any wind and I was dressed for the conditions so I was generally comfortable in spite of the Arctic air mass sitting on top of us.

My first task was to mount the Zone Controller to the face of the ceiling tunnel above the Combi.  I then completed the cable connections and dressed the cables.  We then pulled the #10 2+g cable from the old Aqua-Hot bay to the Combi and I completed the connections for the 120 VAC electric heating element.  We pulled two lengths of two-conductor low voltage cable from the bedroom closet to the fresh water pump, which is mounted on a vertical plywood plate on the rear wall of the bay next to the Combi.  One cable brought +/– 12 VDC down from the 12 VDC distribution panel in the closet where the negative (DC ground) was connected to the pump.  The other cable was used to route the +12 VDC back to a switch in the closet and then return it to the bay where I connected it to the pump.  With this arrangement Butch has DC + and – in the bay and can add a switch later (or use a jumper) to turn the pump on from there.  Although a bit unusual there is nothing fundamentally wrong with wiring switches in parallel; it just means that ALL switches must be off for the device to be off.

While I was working on the wiring in the Combi bay, Butch and Fonda pulled a pair of #4 welding cables from the battery compartment to the bedroom closet to provide + and – 12 VDC to the low voltage distribution panel.  He and I then pulled the remote panel cable for the Combi from the bay up into the bedroom closet.  He took care of the connections at the remote panel while I took care of the ones in the bay.

Oasis Combi Zone Controller (top).

Oasis Combi Zone Controller (top).

With the Combi wiring done I took a few minutes to move all of the parts and supplies I had stored in their (unheated) warehouse into their (heated) parts room where Fonda had cleared some shelves for me.  By the time I was done Butch was ready to move to the next part of the Combi installation; running the coolant lines.  He discovered that his insulated heater hose would not fit over the fittings on the ends of the fan-coil heat exchangers but might fit if he cut off the enlarged swaged ends.  It turned out that the insulated hose still would not fit so he made a quick run to town for regular heater hose. Sometimes bus projects are just like that and you have to figure out how to make things fit and work.

While Butch was gone I spent some time working in the back TV cabinet of my coach.  I tapped into the +/– 12 VDC wires that supply power to the fluorescent light fixture to provide power to the dual 12 VDC outlets and relay I installed yesterday.  The DC negative went directly to the outlets and the DC positive went to the common terminal on the relay.  I connected the positive lead from the outlets to the NC (normally closed) contact on the relay.  All of the relay connections were made with insulated spade connectors.

When I can get a +/– 12 VDC chassis battery cable to the cabinet I will use it to control the relay and move the outlet positive connection to the NO (normally open) terminal.  With this arrangement, the power for the PressurePro Repeater will come from the house batteries (which are rarely switched off) but the unit will only be on when the chassis batteries are on.  For now, however, we will simply have to remember to plug the repeater in when we are going to drive the bus.

That's our bus!

That’s our bus!

As soon as Butch returned all three of us got busy working on the coolant lines.  First Fonda and I pulled the insulated lines out.  Butch then fed a standard line from the front heat exchanger through the floor to the front driver side bay.  Fonda and I then fed it through the access holes to the rear driver side bay and through the floor to Butch by the rear heat exchanger.  Butch connected the hose to rear heat exchanger.  He then pulled the line back up by the front heat exchanger as we removed most of the slack in the bays and connected it to the front exchanger.  Fonda and I fed a piece of hose along the back wall of Combi bay and up into the bedroom closet where Butch connected it to the rear heat exchanger.  I then routed the hose and Butch connected it to the Combi.  Butch fed a second hose from the front exchanger through the floor and we routed that one to the stacked plate heat exchanger one bay forward of the Oasis Combi.  He connected the hose to the front exchanger and I then climbed into the bay, routed the hose with Fonda’s help, and connected it to the heat exchanger.  Butch fed another piece of hose from the Combi bay to the bay where I was working.  I attached that hose to the heat exchanger and then Butch pulled out the slack and connected it to the Combi.  At that point we had a complete, closed loop with the three heat exchangers in series.  I think that was about when the UPS truck arrived with my SHURflo Everpure ADC water filter cartridge for under the kitchen sink.

It was time to make it work; sort of.  Butch had not tied the diesel fuel lines in yet, and the fresh water connections were also not done, but that did not matter.  The next step was to fill the coolant loop with coolant (anti-freeze) and purge it of air.  We thought we had to have at least one of the thermostat circuits active, and thought they worked by grounding the wire coming out of the Zone Controller, but figured out later that we had it backwards.  No harm done, just no good either.  Butch put the 3-way “Summer/Winter” valve in what he thought was the Summer position, which just connects the output (supply) port to the input (return) port, and turned the Bypass switch on the Zone Controller ON, activating the built-in coolant circulation pump.  The Combi was already full of coolant and in this configuration should have just circulated it internally.  Butch was watching the radiator cap and had additional coolant ready to add if any air got purged.  We could hear the pump running, but he could not see any fluid motion in the radiator fill tube.  Hmmm, yet another bus conversion mystery.

Close up of the dual 12VDC outlet and control relay in the passenger side rear corner cabinet.

Close up of the dual 12VDC outlet and control relay in the passenger side rear corner cabinet.

Butch turned the valve to the Winter position which is supposed to allow coolant to flow through the external loop.  This should have caused a drop in the reservoir level, requiring additional coolant, as the coolant was transferred to the coolant lines, but again, there was no flow.  The two heat exchangers in the house (living room / kitchen and bedroom / bathroom) have bleeder valves to help rid the system of air.  I opened the valve on the rear (bedroom) heat exchanger but that did not help.  Butch decided to call ITR for technical support.  He talked through the details of the installation but they did not have any definitive advice.

All indications were pointing towards some sort of blockage internal to the Combi and Butch thought it might be ice.  Kevin, in Washington passed Butch to Marcello at the factory in Canada, but still no luck.  We decided to turn on the electric heating element and set up a small electric space heater to warm up the bay and the unit while we went to dinner.  We drove to The Old Mill west of town on SR-16 where I ordered a mushroom, onion, jalapeño pizza, light sauce, no cheese, and extra thin crust.  It turned out quite well.  When we got back to the house we gave the Combi another try and it looked like it was going to work, but then didn’t.  At that point we called it quits for the night.  Linda called around 9 PM and we chatted briefly, catching up on the events of the day.  Grand-daughter Madeline finally called her “grandma” for the first time, so she was very excited about that, and it was good note on which to end another long, productive day.

2014/11/15 (S) Houston, We Have Ignition

I was up a little before 8 AM, had some more of the stolen I bought at Aldi’s for breakfast, and made about five cups of Teeko’s Seattle Blend coffee.  Butch and I then got back to work on the Oasis Combi hydronic heating system.

Butch was up earlier than me and drove into Logansport before I got up.  When he got back his first task was to remove the supply and return lines (heater hoses) so he could install shutoff valves.  It turned out that he had the wrong parts and had to go back to Logansport so I rode in with him.  When we got back we finally got to work.  It was chilly but we had another mostly sunny day on tap with light-to-no wind, so working outside was not unpleasant.

Fresh water pump on isolated plywood panel behind Oasis Combi.

Fresh water pump on isolated plywood panel behind Oasis Combi.

Butch got the valves installed and the lines reattached.  He then plumbed in the two fuel lines (supply and return).  Before he turned the unit on I pointed out what I had discovered in the manual last night; that the position of the “summer/winter” loop 3-way valve was the opposite of what we thought it was.  With the valve in the “winter” position, which would allow coolant to flow through the loop with the heat exchangers, he turned on the bypass switch on the Zone Control Board.  The circulation pump came on and the coolant level immediately started to drop in the filler neck, which meant the coolant was being moved into the loop and whatever had blocked this from happening yesterday had cleared up.  He turned the pump off so we could stage one gallon jugs of antifreeze/water mixture to finish filling the system.

Butch suspects there was an ice plug in the domestic hot water heat exchanger which is internal to the Combi box and the first place hot coolant goes before it leaves the unit and travels through the coach.  We also suspect that the use of the 1500 Watt electric heating element last night melted the ice plug.  At least that’s our best guess as to what the problem was.  The reason we thought this was the cause is that the factory apparently tests the units with water and it is probably impossible to get it all out using compressed air.  That is certainly the case with an Aqua-Hot.

Butch prepared six gallons of antifreeze/water mixture and staged them by the Combi.  With a funnel in the filler neck he turned the bypass switch on again and started adding the coolant mixture as the pump pushed it through the system.  Once the system seemed to be full I went into the house portion of the bus and barely opened the bleeder valve on the bedroom heat exchanger.  I got a three second puff of air and then coolant started to appear so I closed the valve.  I repeated this with the bleeder valve on the front heat exchanger with the same result.  These two valves are the highest points in the loop, so air tends to collect there.  The system essentially had no air in it at this point.

fan-coil heat exchanger

fan-coil heat exchanger

Butch hooked up the two fuel lines (supply and return), turned the power on to the unit, and then turned the burner on using the switch by the bedroom utility closet.  We could hear the pump trying to prime but the burner would not ignite.  The unit “flamed out” and Butch reset it several times to no avail so he turned the burner switch off.  We studied the situation and Butch realized that he had reversed the fuel lines.  He switched them and turned the unit back on.  It fully primed on the second try and ignited!  Finally, we had ignition.

Butch rigged up temporary power to the fans on the two heat exchangers and let them run.  The coach eventually got too warm to work and we had to turn the fans off.  We spent the rest of the day, with help from Fonda, completing other aspects of the system installation.  I removed an old mechanical thermostat from the warehouse and Fonda cleaned up an identical one.  We had a third one (different make) that did not need any work.

We pulled three two-conductor thermostat cables from the Combi across the bay and up through a hole in the floor of the bedroom utility closet and then to the three thermostat locations.  We used colored electrical tape to tag the ends of each cable as we pulled it so we could keep them straight later; yellow for the living area, blue for the bathroom, and red for the bedroom.  I mounted one of the thermostats in the kitchen by the front living area, the second one by the bedroom, and the third one in the bathroom.  I completed the connections in a somewhat unusual way.  The cable had a red wire and a white wire.  The white wire was left intact and provided a path from the thermostat to the Combi for DC negative (ground).  The red wire was cut in the utility closet and used to provide +12VDC to the thermostat.  The red wire in the cable from the closet to the Combi was not used.

The Combi came with pigtail harnesses that plug into keyed sockets on the Zone Control Board (box) and have butt splice connectors already installed on the loose ends of the wires.  I completed the thermostat wiring by connecting the wire for the front thermostat to Zone 1, the bathroom thermostat to Zone 2, and the bedroom thermostat to Zone 3.  Butch had connected a wire to the Zone 4 connector yesterday and planned to leave it and connect it to a switch in the bay for test purposes.

With the thermostats wired in Butch worked on the fan control relays while Fonda and I pulled a four-conductor thermostat cable from the Combi across the bay, up through the floor into the utility closet, and all the way up the center isle of the bus to the dashboard.  When then took the cable back into the bedroom and pulled it from the utility closet through the driver-side chase to the cabinet at the front end of the kitchen counter and then down through the cabinet to the very bottom and out the front facing grill to the front heat exchanger.  We left plenty of cable for hooking up the fan control relay that Butch had mounted on the fan-coil heat exchanger and left an extra coil of cable in the utility closet so I would have enough wire to make connections to the relays for the fans on the rear heat exchanger.

As with the thermostat wiring, I left the green and white wires intact all the way from the front heat exchanger to the Combi.  In the utility closet I removed the jacket from a six inch section and cut the red and blue wires.  The red wire coming up from the Combi was connected to the relay for the bedroom fan and the blue wire coming up from the Combi was connected to the relay for the bathroom fan, both of which draw air through a common radiator.  These colors matched the colors of electrical tape used to identify the corresponding thermostat cables.  I connected a separate white wire from the DC negative terminal on each relay to the DC negative (ground) bar on the 12 VDC distribution panel at the top of the utility closet.  The red and blue wires from the closet to the front heat exchanger were not used.

Adding coolant to the ITR Oasis Combi.

Adding coolant to the ITR Oasis Combi.

I mounted the relays to the outside wall of the closet; bedroom relay to the rear, bathroom relay to the front.  I do things like that when I work on projects like this.  By this time it was dark and Butch had gone inside not feeling completely well.  He was really stressed out yesterday when we were unable to fill the coolant loop and purge it of air and he did not get a good night’s sleep.  Been there, done that, didn’t even get the T-shirt.

It was going on 6 PM and I was done working for the day, the first day since I have been working here that I had finished up that early and the first day that I had not worked on any of my own bus projects.  But that was OK;  Butch and Fonda’s ability to use their bus conversion during the winter with comfort and convenience was directly related to the successful completion of the Oasis Combi installation and it felt good to have it so close to bring done.  I will finish up the little bit that remains to do tomorrow and then install another 120 VAC circuit from the inverter circuit breaker panel to outlets for the bedroom.

I need to mention that Butch has been very pleased with the treatment and communication from International Thermal Research, the manufacturer of the Oasis product line.  He was on the phone with their U.S. sales office yesterday when we ran into difficulty and they transferred him to someone at the factory in British Columbia.  The factory contact sent Butch an e-mail, which gave him an address to reply to, and his personal cell phone number.

Sometime in the late afternoon Bill Tharpe showed up to continue working on Brittiny’s car.  It needs a new intake manifold gasket, which requires the disassembly of the top half of the engine.  Bill really knows his way around cars having worked with Indy and Formula (One?) race car teams over the years.  Around 7 PM we headed into Logansport to have dinner at Pizza Hut.  I had the salad bar and some decent (smooth, mild) decaffeinated coffee.  When we got back to their house Bill got back to work on the engine and I retired to my room for the evening.  Butch and I talked earlier about possibly driving over to the Ft. Wayne Hamvention tomorrow but decided to stay here and continue working on bus projects.

2014/11/16 (N) Death of a Mouse

I was up around 8 AM and had my usual breakfast of homemade granola, some orange juice, and coffee (Teeko’s Seattle Blend).  I still had some of the stolen left, but having had that the last two mornings I felt the need to return to my normal routine.  Right after breakfast I replaced the GFCI outlet in the bathroom.  The old one had tripped a couple of times for no apparent reason and that was just one more thing I did not want to live with.  The old one was feeding two load circuits and had short pigtail wires wire-nutted to the hot and neutral conducts.  GFCI outlets are much bulkier than normal ones so that made for a very crowded box.  The new one had back connectors that allowed two wires to be inserted straight in under one screw and tightened.  That allowed me to do away with the two pigtails and the two wire nuts and make it a bit easier to get the outlet into the box.

By the time I finished installing the GFCI outlet Butch was ready for my assistance.  He finished connecting the fan relays on the front heat exchanger and I finished connecting the fan relays on the rear heat exchanger.   I then tied in the fan relay lines to the appropriate fan control lines coming out of the Oasis Combi Zone Control Board.  With the burner switch turned on I tested each zone by turning its thermostat up until it clicked, causing the burner to ignite, the circulation pump to start, and the fan(s) to come on.  All three zones worked.  Although not as dramatic or emotional as yesterday when got the unit to fill, purge, and ignite, this meant we were done with the Oasis Combi installation (except for some purely cosmetic things that Butch and Fonda may not get to for a while) and that it was fully functional.

Top of the Combi showing summer/winter valve lower right (blue handle).

Top of the Combi showing summer/winter valve lower right (blue handle).

While I was working on the Oasis Combi fan control wires Butch started working on installing a fuel gauge.  The New Jersey Transit MCI MC-9B coaches did not have fuel gauges as they made regular runs of known distances and returned to the same NJT garage every day.  For cross-country RV use, however, a fuel gauge is a very good thing to have.

To install the fuel gauge Butch had to pull the instrument cluster out of the dashboard.  These things are rarely designed/built for easy servicing, and this was no exception, but he got it out.  He had installed the sending unit in the fuel tank a long time ago but never hooked it up.  He managed to run a fishtape up from the driver-side front bay into the area behind the dashboard.  He attached a wire to it and fed the wire in as I pulled the fishtape out.  We then used the fishtape to feed the wire from the driver’s side of the generator bay to the passenger side.  From there the wire had to go through the chassis battery bay to get to the sending unit on the fuel tank.  After drilling a hole in one panel and drilling out two rivets holding an unused fuse holder to another panel we finally had a route for the wire.

There was a blank spot on the instrument cluster where the fuel gauge would have been so that is where Butch installed it.  It took us a while to decode the 24 VDC dashboard wiring diagram but we eventually figured out that there was an unused screw terminal on the load side of the Master Switch just below the fuel gauge that would very conveniently provide the +24 VDC for the gauge.  I made that connection and then Butch connected the instrument, remembering to pass the wires through the dashboard hole first.  In addition to the +24VDC, signal, and ground for the gauge he had to tap into the 24 VDC instrument lighting circuit to power the instrument light and provide a ground connection for that as well.  With everything hooked up Butch turned on the Master Switch and the fuel gauge indicated just below a full tank, which is what he expected.  These kinds of “little” projects sound relatively simply, but they always seem to take a half a day to a full day to do, even with two people working on them.

At this point it was about 2 PM so I took a quick lunch break and had a tofu hotdog with mustard, relish, and onions.  We had hints of snow flurries during the morning that became more persistent after noon.  I was thinking about installing the new Shurflo Everpure ADC water filter cartridge under the kitchen sink and opened the cabinet door to have a look at what was involved.  (Actually, I knew what was involved having done this before.)  This filter cartridge should be the easiest thing in the world to remove and install but that has not been my experience.  The location of the filter head doesn’t make it any easier.  Anyway, I turned on the light and noticed a waded up paper towel in the trash can.  I had not been using this trash can since I realized that the resident mouse had easy access to the area under the sink and regarded the waste basket as a buffet.  I figured I had thrown this used paper towel in there by mistake out of force of habit as I catch myself several times a day starting to do that.  I moved the can and reached in to get the paper towel and that’s when I noticed the dead field mouse in the corner of the trash can.

The mouse was a tiny creature, gray on top and white on the bottom.  I surmised that it had returned to this cabinet looking for the food it had found there on previous occasions, climbed up a carpeted wall or electrical cable, perhaps walked across a drain pipe and, seeing the paper towel moved to the rim of the trash can (the only place I ever actually saw it alive) and either jumped or fell in.  Unfortunately (for the mouse) the trash can did not have a plastic liner bag and so it had no way to escape.  I presume it died of thirst and/or lack of food.  It was not my intention to use the trash can as a trap.  In fact, I had purchased a live trap a few days ago but not yet set it.  My plan was to trap it, unharmed, and release it a couple of miles away near a creek so it had access to water.  Instead, I added it to my real trash bag, tied up the bag, and put it in the dumpster.  Although I was glad to no longer have it roaming around inside the coach, I was saddened to find it dead and to think that it had died this way.  I have no way of knowing, of course, if this was the only mouse in the coach so I will continue to be on the lookout for telltale signs of the presence of mice.

I returned to working on Butch and Fonda’s bus.  While they dressed up some coolant lines and tightened up some fittings on the Oasis I installed four surface mount duplex electrical outlets in the bedroom, two on the back wall above a narrow shelf at the head of the bed, one in the driver side chase at the midpoint, and one at the front end of the chase inside the utility closet.  I turned off the power to the inverter panel, removed the cover, and routed the cable down into the box.  Butch discovered that he did not have any more 20A circuit breakers so I connected the ground and neutral and left the load wire until we had an appropriate breaker.  We were done working in/on their bus for the night, so I left the cover off of the inverter panel and turned the power back on so they would have lights in the front part of the bus

Fused DC distribution house panel in MC-9 bedroom utility closet.

Fused DC distribution house panel in MC-9 bedroom utility closet.

Throughout the day Butch had been adding to a list of things he needed and at this point the list was long enough, or the items critical enough, that we made a run to town.  By this time it had been snowing for a few hours and it was accumulating on grassy areas and making the roads slick.  Unfortunately the Logansport Home Depot closed at 7 PM on Sunday evenings and we got there at 7:05 PM, having stopped first to fuel up the Suburban.  No problem, we just drove down the street to Rural King which was open until 9 PM and has free popcorn.  Bonus!  Butch found most of what he needed there.  My shopping list was short and easily filled at Walmart where Butch picked up a few other things on his list.

When we got back I made a tofu “turkey” sandwich with vegan mayonnaise, sliced onions, and power greens and got out some of the seedless black grapes.  As I was finishing the preparations Fonda came to the bus to let me know that Linda was on the phone.  I brought everything into the house and chatted with her for a little while.  We then sat down and ate dinner.  After dinner I used Butch’s chop saw to cut my oak center pillar mounting board to length and then set it up on a table in the parts room so I could stain it.  Fonda got the stain, a shallow wide mouth can, a disposable foam brush, a rag, and a pair of disposable gloves for me to use.  I was not very happy with the results, but I will see how it looks in the morning.  I suspect I will end up painting it flat black.  I would really like to get it mounted to the center windshield pillar before I wrap up working on my bus this Wednesday but, given the other things I need to do, it’s going to be close. 

 

2014/10/16-22 More Bus Work

2014/10/16 (R) More Wiring

Butch had to go to Logansport this morning for parts and groceries.  I stayed behind to continue working on the AC wiring for their bus conversion; after breakfast, of course.

I mounted two 6-position AC main lug panels, one above the other, to the right of the 20-position panel we installed yesterday for the inverter circuits.  The panels I installed today were for AC circuits that only run on shore power or the generator, not the inverter.  The reason for two panels was: A) Butch already had them, and B) they were narrower than the larger panels and would fit in the available space on the right rear wall of the closet.

I had tied the main shore/generator power line to the inverter AC input line last night so the refrigerator, which is wired through the inverter panel, would have power overnight.  I left those tied together for most of the day so the lights would work.  I pulled all of the existing circuits that we disconnected yesterday into the boxes, dressed the wires, and connected/mounted the circuit breakers.  By the time I finished Butch had returned from his morning errands.  He connected the shoreline and I checked to see that we had 240 VAC between L1 and L2 and 120 VAC from each line to the neutral conductor.  He then disconnected the shoreline and made sure the generator was off.  Using the inverter to power a work light, I pulled the main power cable into the lower box and secured it.  I then pulled the cable that feeds AC power to the inverter into the lower box and connected it to a 30 Amp breaker.

MC-9 house wiring.  Inverter panel on the left, shore/genset panels on the right.  DC upper left, solar upper right.

MC-9 house wiring. Inverter panel on the left, shore/genset panels on the right. DC upper left, solar upper right.

I plugged the shoreline back in but got a low voltage with no current on L2 and an Error Code 6 on the Progressive Industries EMS remote monitor display.  Butch checked the plug and I just did not have it fully inserted into the outlet.  Once he fixed that we got the correct voltages and no errors.  We checked each circuit and everything checked out perfectly.

(Note: The shoreline is wired for “50 A” RV service, which is 240 VAC service from L1 to L2 but with an active neutral that provides two 50 A, 120 VAC power feeds with L1 and L2 180 degrees out of phase.  As a result the currents in the neutral wire from L1 and L2 cancel rather than add.  Butch has his generator wired for 120 VAC output and has L1 and L2 tied together on the generator side of the transfer switch.  This makes the full 100 A output of the generator available to be shared between L1 and L2 in any proportion.  Although this system can supply a full 50 A of current on both L1 and L2 at the same time, it could also supply 70 A or one and 30 A on the other unless this is prevented by circuit breakers.  Also, regardless of the distribution of current between L1 and L2 the currents will add in the neutral as much as 100 A of current.  Although sensible load management would prevent this from ever happening it is entirely possible to draw 30 or 35 A on each leg and end up with 60 – 70 A in the neutral.  Thus, when designing your house AC electrical system this way, provision should be made for a neutral conductor that is sufficient to carry this amount of current.  The advantage to doing your system this way is that the voltage regulation will be better under load than with a 240 VAC generator powering imbalanced 120 VAC loads on both legs as the 240 VAC configuration regulates the voltage between L1 and L2 but the voltage from L1 to N and L2 to N can be off substantially.)

Butch needed another non-inverter circuit for the front of the bus so we pulled a 10-2+g Romex cable from the electrical closet along the driver’s side wall/ceiling area and down into the cabinet at the front end of the kitchen counter. He and Fonda spent a bit of time cutting openings in the end of the cabinet for a two-gang outlet box and a single-gang outlet box.  The two-gang box was for a pair of duplex outlets fed from the inverter panel and the wires were already run.  The single-gang was for the new circuit we just pulled.  When they were done I disconnected the shoreline so I could safely tie the new circuit into the lower panel.  I then installed the cover plates on all three boxes and plugged the shoreline back in.  We had the breaker turned off for the new circuit while I wired the outlet.  I then energized it and it tested OK.

I repositioned a 12 VDC fused distribution box above the inverter panel and mounted it.  I then moved a terminal strip for their solar panel wiring to a slightly different location to open up a space for Butch to drill a hole.  At that point we were done working for the day.  I changed into my non-work blue jeans and relaxed for an hour before dinner.  During that time Butch called Jaral Beatty, a cabinet maker in Logansport and personal friend of Butch’s, and put me on the phone with him to see if he could come to Twelve Mile and finalize plans for a custom desk and printer cabinet for the bus.  The weather forecast for tomorrow is for mild, mainly sunny, conditions and Jaral said he could come out mid-afternoon.

Butch and Fonda’s younger daughter, Brittani, and her husband, Sterling (Rock), were expected for dinner at 7:00 PM so I fixed a salad and heated some Amy’s chili for my dinner.  Dinner was jovial and the first time I have eaten with Butch and Fonda at home on this latest round of working visits.  Butch called Joe Leibherr and put me on the phone with him.  Joe and Connie own the lot in Quartzite where we plan to spend part of the winter and I had a few questions for him.  (Dale and Sherry Leibherr bought most of Butch and Fonda’s business assets.  Dale is Joe and Connie’s son.)  I had a nice long chat with Joe and was satisfied that it will be an OK place to spend part of the winter.  Besides the full hookup 50A sites there is a laundry on site and Wi-Fi.  Verizon cellular service is also apparently very good.  Joe filled me in on some of things to do in town and suggested we bring our passports and visit Los Algodones, Mexico while we are in the area.  Brittiny and Rock stayed until 11:30 PM so it was a nice, long visit.  We were all really tired by the time they left and immediately turned in for the night.

2014/10/17 (F) VDO Air Power

After Brittani and Sterling (Rock) left last night I retired to the guest bedroom immediately but was up for a couple of hours responding to e-mails and writing my daily blog entry.  I do not shut my computer down every night but I do shut it down occasionally, especially if there are updates available.  Last night there were 28 updates.  I was not up at the crack of dawn today, which was a shame as it was the nicest weather day we’ve had for the week just past and looks to be the nicest of the week ahead.  Butch was up late last night as well, so we were both dragging a bit this morning.

Following breakfast I readied the coach for travel, securing loose objects inside and checking that all of the bays were shut tight and locked.  I switched on the chassis batteries and air valves, unplugged the shorepower cord, and went for a short test drive to calibrate our new VDO electronic speedometer.  Butch mentioned that there was a funeral home on the northwest corner of SR-16 and US-31 where he had easily turned their bus around in the past.  That turned out to be just what I needed for my test run as it kept me from having to go south on US-31 in order to make a U-turn to get headed back to Twelve Mile.

I had driven the coach last Sunday from Elkhart to Twelve Mile with the new speedometer set to its default pulses per mile and it indicated less than 1/8th of the actual speed as shown on our Rand-McNally 7710 RVND GPS.  When I got to Twelve Mile I calculated the pulses per mile I thought would be close to correct and programmed that number into the instrument.  On the first leg of my test drive this morning the indicated speed was still about 1/8th of actual.  Either my programming did not “stick” or I based my calculation on a grossly inaccurate assumption.

I pulled into the far entrance to the funeral home parking lot and made a broad turn to get lined up with the other entrance.  I switched off the ignition, held down the button on the face of the VDO, turned the ignition back on, and started the engine.  The speedometer cycled through its three calibration modes and I stopped it on ADJUST and then selected UP as the direction the needle needed to move.  The adjustment was a little tricky, especially while driving, but I figured out how to switch it between up and down.  I got it adjusted to my satisfaction before getting back to Twelve Mile and after not adjusting it for a minute or so it reset and reverted to its standard speedometer/odometer display, only this time showing the correct speed and recording the correct mileage.

When I got back to Butch and Fonda’s house I pulled the bus around, blocking the street temporarily, and backed it in next to theirs.  Fonda helped spot me for the final few feet.  Instead of shutting the engine off I let it idle while I got my four chassis stands out of the warehouse and positioned them at the four corners of the bus.  I put the engine in high idle and raised the body as high above the axles as it would go.  I slid the stands into place under four frame members, dropped the idle to low, and gently lowered the bus until it was resting firmly on the stands.  With the bus sitting on the stands it will now be safe to work underneath it when we get around to those projects.

The next project was to replace the air filter / water separator for our auxiliary air system.  Butch did most of the work on this project.  He disconnected two air lines from the existing filter assembly, which includes a pressure regulator and a Schrader valve, and then unscrewed the mounting bracket from the rear wall of the bay under the driver’s seat where a lot of the auxiliary air system is housed.

With the old unit out of the bus he was able to work in his shop to remove the inlet and outlet fittings and clean them up on a wire wheel before reusing them.  He installed the old fittings in the new housing using pipe thread compound and matched the alignment of the old unit so the air lines would fit back on to them.  The two machine screws that were used to mount the old unit’s mounting bracket to the wall were too big for the slots in the new unit’s mounting bracket so Butch used his Bridgeport vertical mill to slightly enlarge the upper slots.

With the shop work done I took everything back out to the bus and installed it, which consisted of attaching the two air lines (with compression fittings), attaching the mounting bracket to the housing, attaching the mounting bracket to the rear wall of the compartment, and then tightening the two air line nuts.  Butch checked my work and snugged the air line nuts another partial turn.

I turned on the auxiliary air compressor but it seemed to take a long time to start to build air pressure and Butch heard and felt a leak at the unloader valve coming out of the auxiliary air compressor.  I shut of the aux compressor and he hooked up his portable air compressor to the air hose fitting in the passenger side engine bay which brought the pressure up in the auxiliary system very nicely.  We turned his compressor off, turned the aux compressor back on, and bled enough air off to cause the aux compressor to run.  It finished bringing the pressure up to the cutout value without difficulty.  I sprayed all of the fittings with Simple Green and did not detect any leaks.  We had noticed earlier that the lower half of the filter housing, which locks and unlocks in only 1/8th of a turn, had a loose fit.  Once the system was pressurized, however, it tightened up.

Norgren auxiliary air filter / water separator (lower right).

Norgren auxiliary air filter / water separator (lower right).

The old unit had to be replaced because it was no longer made and the replaceable filters were no longer available.  Once we had it out of the coach and disassembled I was surprised by how badly deteriorated it was internally.  Aluminum, by definition, does not “rust” but it certainly can and does corrode (oxidize).

Butch and Fonda spent part of the day building and installing a slide out tray for one of the passenger side bays.  It will hold his tool box on top and have room for miscellaneous storage underneath.

I got the Zena power generating module wiring diagrams for Butch to study while I ate lunch.  We were just getting ready to start working on this when Jaral showed up.  He and Butch and Fonda talked for quite a while about personal stuff while I started probing around in the driver side rear electrical bay for a place to tap into an ignition switched source of 24VDC power.  I located a relay that looked like it would do the trick (R53).  I broke off working on this to spend time with Jaral, who rode his scooter from Logansport to discuss some cabinetry project.

Jaral looked at Butch’s projects first as they are immediate.  He then looked at what we want to do with the front part of our coach.  We need to have a desk and a printer cabinet built out of walnut to match the woodwork that is already in the bus and Jaral is our cabinetmaker of choice.  It sounds simple enough, but the reality is more complex.  After talking it through with him (again) and taking some measurements we agreed that I need to make very careful dimensioned drawings of exactly what we need.  I may try to do that over the winter but worst case is that it will have to wait until next spring and probably after we have removed the current furniture.

Butch and I worked on the Zena wiring for a little while after Jaral left.  We determined that the two blue wires in the electrical bay ran to the Zena control modules in the engine bay and to the fan terminals on the Zena rectifier assembly in the house electrical bay.  He had a tandem spade lug adapter that we used to tap into the power to the coil of relay 53.  With the coach batteries on but the ignition off we did not have power to the fans on the rectifier assembly or the control modules in the engine bay but with the ignition on we did.  That was a small but important success.

The weather had turned cloudy, windy, and chilly as the afternoon progressed.  We spent a little while studying my house electrical bay and discussing how I might get the large battery charging cables from the ceiling-mounted rectifier to a Class T fuse and then to the batteries.  I decided that was a problem I was not going to solve in the remaining hour of daylight and called it a day.  By then it was 6 PM so I went to my coach to have dinner which consisted of a salad, tofu hot dog, apple, and a glass of Franzia Moscato.  I retired to the guest bedroom around 9 PM, worked on my computer and iPad until about 10:30, and then turned off the lights.

2014/10/18 (S) Cold Wet & Windy

Even though I went to sleep at 10:30 last night I did not get out of bed until 8 AM this morning.  Today’s weather forecast was for a 50% chance of rain with winds out of the WNW shifting to N at 15+ MPH and a high temperature of 50 degrees F.  The 50% chance of precipitation turned out to be an all-day drizzle; not an ideal day for working outside.  Nonetheless, I spent the late morning (post breakfast) working in our house electrical bay on the wiring for the Zena 24 VDC power generating system.

The only thing I actually accomplished was mounting a Class T fuse holder (with a fuse) to the ceiling of the compartment.  That was a bigger accomplishment than it seems, however, as its location determined the lengths of the cables needed to finish the project.  With a nicer day on tap for tomorrow I expect to get those cables made and installed.  A final check of the wiring and installation of the drive belts on the alternator will complete the project, which I stated almost exactly two years ago.

20141018-09012

Zena rectifier (upper left) and Class T fuse (upper center).

 

Butch and I went to Logansport in the early afternoon.  He needed plumbing parts for his fresh water tank and ITR Oasis Combi project.  I needed 2/0 lugs for my battery cables, some 3/8 compression nuts and sleeves, and some duplex outlet expanders.  I found the lugs at Rural King (where we also got some free popcorn) and everything else at Home Depot.  These stores happen to be conveniently located across the street from one another.  The nuts and sleeves will be used to rig up a hose or tube so we can test the water flow coming out of the pipes that feed the kitchen faucet.  The flow is much lower than it should be and we want to determine if it is due to the faucet or upstream in the piping.  I found a small duplex to 6-out expander that would fit under the thermostat on the end of the kitchen counter based cabinet.  I also found a duplex to 6-outlet expander with integrated surge protection and two USB charging ports.  I bought two, one for the outlet on my side of the bed and one for the outlet on the outside wall just behind the passenger seat.  This model is not illuminated like the one I installed on Linda’s side of the bed, but that’s OK.

We stopped at Butch’s parents’ house to investigate the source of a mechanical noise. It turned out to be a dehumidifier in which the fan motor bearings were squealing.  Butch loaded it in his truck to take back to his house where he could more conveniently try to oil the bearings.  We chatted for a while and then headed to Martin’s Supermarket so I could pick up a few grocery items.

When we got back to Twelve Mile I unloaded and stored my groceries and then installed two of the three outlet expanders.  I could not install the one by the passenger seat as the outlet was too close to a wooden structure.  There is an outlet box with a solid cover plate next to the duplex outlet and I will see if the outlet can be moved over.  If not, I will install this unit behind Linda’s night stand at our sticks ‘n’ bricks house.

Butch’s brother, Tom, showed up and the two of them worked on installing the Blue Ox base plates on Butch’s Suburban.  I spent the afternoon making a scale drawing of the passenger side of the front half of the coach showing the two Lambright Comfort Chairs, custom printer cabinet/table, and custom desk with pantry.  I checked in with Butch and Tom and helped them a little bit with the base plate project.  When they reached a stopping point, or at least a point where my assistance was no longer needed, I returned to my coach and fixed dinner.

I had a salad of power greens with cranberries and peanuts, some apple sauce, and the leftover Mjadra from La Marsa, the last of my frozen leftovers from our dinner at the Brighton location with Bruce and Linda Whitney.  A glass of Franzia Moscato was quite agreeable.  Butch and Fonda had not eaten their dinner yet, so I worked in the guest bedroom at my computer while they ate.

Linda called around 8:45 PM and chatted with Butch about an accounting issue related to their business and then chatted with me about our grand-daughter, Madeline, who is finally pronouncing words clearly enough to be understood and quickly developing a spoken vocabulary.  Brendan and Shawna brought her to our house around 11:15 AM this morning and stuck around through lunch to get her down for her nap and then took off.  Grandma Linda had her all to herself the rest of the day and will have her tomorrow until they pick her up.  I chatted with Butch and Fonda for a while after that and then retired for the evening, checking and responding to a couple of e-mails, doing a little web-surfing, and working on this post.

2014/10/19 (N) Of Mice And Men

Although I really enjoy Linda’s homemade granola I decided to make toast with some of the Brownberry Country White bread I bought.  I was surprised to discover that someone, or something, had chewed a hole through the plastic bag and eaten some of my bread.  A mouse, no doubt, but I only bought this bread on Tuesday, so it was a recent visitor.  The surprise was that the bread was in a cabinet that I assumed was inaccessible to mice.

I emptied the cubby and discovered a hole in the back wall big enough to stick my finger through for some distance, which meant it was plenty big enough for a mouse to get through.  The walls are covered with the same thin carpet that is used to line all of the other cabinets in the coach.  In this case it was applied to fairly thin wood with space behind it.  Butch looked at it with me and we found that the glue used to install the carpet had lost much of its hold.  We lifted it up and found a 2″x2″ cutout in the wood with the hole in the carpet roughly centered on it.  There was a Romex electrical cable coiled up behind the wall with the ends taped.  We presumed the wire had once passed through the hole into the cubby but was now a way for the mouse to travel vertically through the cavity and get to the back entrance.

I threw the bread out, of course and cleaned the counter surface, which forms the floor of the cubby, with Lysol.  Mouse proofing the bread cubby will have to wait until tomorrow but my plan is to feed the wire through the hole in the carpet and then lift the carpet at the bottom and run a bead of caulk (or hot glue) along the joint between the counter and the wood walls.  I will then install a surface mounted outlet over the hole.  At a minimum it will seal the hole and it might prove useful someday for plugging in an appliance, assuming the wires are still energized.

Although it was in the low 30s when we got up this morning, it was finally a decent day for outside work.  The high temperature only made it to the mid-50s but it was sunny most of the day with a light breeze.  Appropriate layers of clothing made for comfort while working.

My main focus today was completing the installation of the Zena 24VDC power generating system in the bus.  I started this project two years ago this month and today was the day to finish it.  I had also written a complete draft of an article about this project for Bus Conversion Magazine but held off finishing and submitting it pending completion of the project.  Now that the work is completed and the system functions correctly I hope to finish the article in the next few weeks.

The purpose of the system is to charge/maintain the 24VDC house battery bank while we are driving the bus, during which time the refrigerator, and other minor loads, are being powered by the inverter.  The system consists of a high-output, continuous-duty, 24VAC, 3-phase alternator driven by the main bus engine (Detroit Diesel 8V92TA).  The alternator feeds a large rectifier assembly in the house electrical bay and is controlled by three interconnected modules mounted in the engine bay near the alternator.  Redundant voltage sense wires run from the rectifier back to two of the three control modules.  The system is activated by ignition switched 24VDC power which we wired up a couple of days ago.

The unfinished part of the project involved the connections between the DC output of the rectifier and the 24VDC house battery bank.  I mounted a Class T fuse on the ceiling of the electrical bay yesterday which then allowed me to determine several cable lengths.  On the +24VDC side I made three cables from 2/0 welding cable as follows:  1) Rectifier DC positive to ceiling fuse terminal A; 2) Inverter/charger fuse terminal B to ceiling fuse terminal B, and; 3) Ceiling fuse terminal B to +24VDC battery disconnect switch.  With this configuration both the rectifier and inverter outputs go through separate fuses to a common point (ceiling fuse terminal B) and that point is connected to the battery disconnect switch.  I also made a cable to go from the rectifier DC negative (ground) to the house DC electrical system ground lug; again using 2/0 welding cable.

I used a metal blade hacksaw to cut the welding cable to length and cut through the heavy rubber sheath 1/2 inch from the end to expose the copper conductors.  I attached crimp style through-hole terminals to the ends of the cables and held them in position to get the alignment correct.  I made reference marks to ensure the alignment and then crimped the lugs onto the wire using a very large hand-operated press in Butch’s shop.  Projects like this are a lot more fun with access to the correct tools.

I attached as many cable ends as I could without touching any live voltages.  I turned off the Aqua-Hot, the UPS, and the inverter/charger before disconnecting the main AC shore power.  I then turned the +24VDC disconnect switch to the off position, isolating the coach/inverter from the 24VDC battery bank.  (Note, however, that I did not disconnect the 12VDC center tap.)  With power off I completed all of the needed connections, including the small ground wire for the 24VDC fan on the rectifier, turned the 24VDC batter disconnect switch to ‘on’, and turned the inverter back on.  It immediately started supplying power so I knew my wiring was correct.

Back in the engine bay I checked all of the wiring against my diagram and everything was good to go.  I taped off two wires with bullet connectors on the ends to prevent accidental shorting.  One of the wires is used to reset the system by grounding it and the other wire is tied to chassis ground.  With all of the electrical connections verified I got Butch to help install the two drive belts from the DD8V92TA pulley to the alternator (power generating module).  That was when we discovered that the lower side of the belts were in contact with a pressurized oil hose for the Spinner II centrifugal by-pass oil cleaner.

The hose was secured with zip ties in several places so I clipped and removed those.  I disconnected the hose from the Spinner II and re-routed it to avoid the drive belts and other rotating parts on the front of the engine (which faces the rear of the bus).  I reattached the oil hose to the Spinner II and secured it with zip ties.

Butch used a pry bar to move the alternator and put tension on the drive belts while Tom and I tightened the alternator mounting bolts.  The inverter had been supplying AC power to the coach for a while and a check of the house battery voltage showed +24.5VDC.  I turned on the chassis batteries and engine accessories air valve, started the DD8V92TA, and put it in high idle.  I re-checked the voltage at the rectifier output and it was 24.8, higher than before and rising, but not too high; an excellent set point at least for now.

DD8V92TA with Zena 3-phase alternator lower right.

DD8V92TA with Zena 3-phase alternator lower right.

We observed that some of the belts on the engine seemed loose and floppy.  Butch also noticed what appeared to be a stone embedded in the outside surface of the Gates Hi-Power II PowerBand A92 triple V drive belt that runs from the DD8V92TA crankshaft pulley to the drive pulley for the engine cooling fan.  Butch called O’Reilly’s in Logansport but they were unable to locate the 2.125″ wide triple-V belt in their system.

The oil dipstick tube was also too close to the new drive belts but when I tied to move it (bend it slightly) I noticed that it was very loose.  The fitting at the block was not tight and it was obvious that some oil had leaked out from there.  I slid under the engine from the rear of the bus and tightened it at the block.  (It is nice having the bus supported on stands so I can work under it without concern.)

While I was working on the Zena system Butch installed an outlet fitting on their fresh water tank.  He and Fonda, and eventually Tom (Butch’s brother), re-installed the tank in their bus and then mounted the ITR Oasis Combi next to it, securing it to the floor of the bay.  To accomplish that they had to drill holes, align holes, and determine a location for the water pump, which required more information regarding allowable pump orientation.  Sometime during the day Butch shifted his focus towards an antenna project on the roof of their bus.  He had previously purchased a Tarheel motorized fold-over mount for his large Tarheel screwdriver antenna and wanted to at least get the fold-over mount attached to the roof before they left for the southwest.

The key lock on our passenger side engine bay door was getting difficult to turn so I removed an access panel on the inside of the bay door to investigate the mechanism.  As I loosened the access panel water ran out the bottom.  We determined that the gasket surrounding the handle/lock assembly was dried out and cracked, allowing water in at the top.  I removed the handle/lock assembly by pulling it out of the door from the outside, dried it out, and lubricated it.  I reassembled it for now, but I need to apply some kind of sealant behind the gaskets or get new ones from Prevost (if they are still available).

Prevost H3-40 keyed, non-electric, door lock mechanism.

Prevost H3-40 keyed, non-electric, door lock mechanism.

Butch shifted his attention yet again, this time to their Suburban where he and Tom re-attached the front bumper.  It was removed a few days ago so he and Tom could install the Blue Ox base plate kit which will allow them to tow it with the bus.

As the sun dropped low in the western sky the temperature dropped along with it.  I buttoned up my coach and helped Butch get his tools and supplies moved inside.  I then went to my coach to have dinner which consisted of an Annie’s Spicy Mongolian noodle bowl with added peanuts and a tofu hotdog with mustard, onion, and relish.  A glass of Moscato with the meal and a cup of Oriental Treasure green tea afterwards provided a soothing and warming end to the meal.  I returned to the house and we chatted for a short while before I retired to my room to check e-mail and write.

2014/10/20 (M) Bad Timing

I have settled into something of routine on this extended visit to Twelve Mile, Indiana; up late, sleep late, eat breakfast, get to work.  Usually.  Butch spends the early morning on his computer and is usually ready to work about the same time I am.  Usually, but not always.  Sometimes he gets to work earlier than me, and sometimes much later.  Although we had a beautiful weather day (except for the brief thunderstorm around 10 AM) we were not able to take full advantage of it for various reasons.  I had left the Aqua-Hot turned off over night to see if it would start reliably when cold.  The burner fired after a short 10 second purge.  It was smokey at first, but ran its full cycle and eventually cleared up.  I turned it off and will test its cold start capabilities again tomorrow morning.

We discovered yesterday that the triple V fan belt on my bus engine was worn and had something embedded in it.  The belt was a Gates Hi-Power II PowerBand A92.  We spent some time looking for one online but were not sure we had found exactly the right one so I decided to see if Prevost had it in stock.  They did, and it was only a few dollars more, included free shipping (as always), and would be at my house before I got home.  I ordered two.  This belt drives the engine cooling fan and if it breaks the bus isn’t going anywhere until it is replaced.

Bread cubby with AC outlet base plate.

Bread cubby with AC outlet base plate.

Butch and Fonda worked on re-conditioning a pair of fan-coil heat exchangers that will get tied-in to their new ITR Oasis Combi hydronic heating system on the bus.  Butch and I had both been assembling shopping lists and I was at the point where I needed to get some small parts in order to move forward with some small projects.  We left around 11:30 AM and drove to Logansport where we visited NAPA, O’Reilly’s, Rural King, Aldi’s, Home Depot, and Walmart.  All of these stores are located close to one another on the east end of town except for the O’Reilly’s and NAPA which are just a bit farther down the main road towards downtown.  When it comes down to it, Logansport is just not that big.

By the time we got back it was after 3 PM and we were suddenly very busy as we tried to take advantage of the few remaining hours of daylight.  Butch and Fonda worked on installing the Tarheel fold-over mount and I worked on sealing the bread cubby, installing a Wiremold surface mount outlet over the hole in the back wall, and installing a small battery powered LED puck light in the back closet to illuminate the inverter sub-panel.  I cut a small triangle of thin aluminum for the hole in the corner floor of the bread cabinet and then sealed the joint between the floor (counter) and three walls with a silicone-based paintable tub and tile caulk in a convenient squeeze tube.

LED puck light in rear bedroom closet to illuminate the inverter sub-panel.

LED puck light in rear bedroom closet to illuminate the inverter sub-panel.

When I finished those tasks I checked in with Butch and Fonda and found out that they had run into problems with the Toggler(R) bolts Butch was using and had to undo what they had already done and seal up the holes in the roof for the night.  There wasn’t anything I could do to help at that point, so I started working on the wiring that will allow me to relocate the Magnum ME-ARC remote control/display module from the electrical bay to the house panel next to the refrigerator.  Rather than try to route the 4-wire telephone cable between the inverter/charger and the house panel, John Palmer had suggested two years ago that I re-purpose one of the existing cables that had previously connected the Heart Interface inverter/chargers to their remote displays.  All that was required was to attach RJ-11 plugs on each end to four off the nine available wires.  As long as I used the same four wires on each end, and got the colors in the same order, it should work fine.  Butch already had the necessary crimper and I bought a small bag of the plugs today at Home Depot.

Sunset is just before 7 PM these days.  It not only comes earlier, it comes quickly.  We were done working by 6:30 PM and I withdrew to my coach to have dinner.  I had a nice salad of power greens with sun-dried tomatoes, olives, garlic, artichoke hearts, dried cranberries, and peanuts with peanut butter and crackers on the side and a small glass of Franzia Moscato.  I cleaned up from dinner, closed up the coach, set the two small electric cube heaters for around 60 degrees F, gathered up a few things and went back to the house for the evening.  Butch and Fonda were just getting ready to eat their dinner so I retired to my room to work on my computer.

2014/10/21 (T) Fair Weather Ahead

One of the first things I do each morning, even before I have breakfast, is to check the current and forecasted weather.  The guest bedroom at Butch and Fonda’s place is an interior room with no windows and is well insulated, including the ceiling, so I have no visual or auditory reference to what is happening outside.  If not for the clock on the headboard of the bed (or my various communications and computing technologies) I would have no idea what time it was, or even if it was day or night.

There was widely scattered light rain across northern Indiana at 7:30 AM with single digit precipitation probabilities through the day dropping to zero chance of rain for Wednesday and Thursday with high temperatures in the mid-to-upper 50s.  That is about as good as it gets for the fourth week in October.  Hopefully it bodes well for our project work and will be a very productive few days.

Butch plans to attend a gun show on Saturday morning and needs to spend most of Friday getting ready.  Butch and Fonda’s family members (parents, siblings, children, etc.) are gathering at their house on Sunday to celebrate the holidays early since Butch and Fonda plan to be in the southwest with us this winter.  Given the weather forecast I will probably work the whole day on Thursday, spend the night, and then head for home early Friday morning, or at least as early as I can manage.

Butch’s main focus today was re-mounting his Tarheel antenna lift to the roof of their bus.  He figured out last night what parts he needed to make the installation work after his Togglers(R) broke yesterday.

My main focus was diagnosing and repairing the very low water flow from the kitchen faucet but before I got too deep into that project I called Prevost’s U. S. parts office in Elgin, Illinois to check on a couple of things.  They had the CX-96 cogged fan belts in stock in the U. S. but wanted $90 for a pair (they only sell them in pairs).  I found them last night online for $21 each, so that was a big difference.   They also had the bay door handle/lockset gaskets I needed but they were only stocked in Canada.  They were only $4 each, so I ordered the 12 I need to redo every door.

The disassembled kitchen faucet flow restrictor.

The disassembled kitchen faucet flow restrictor.

I found the installation and instruction manual for the Kohler kitchen faucet in our conversion binder.  It said that the handle and cover should slide straight off of the body once the handle set screw was removed.  Butch and I both tried this but we could not get it off.  While studying the diagram and parts list I noticed a “restrictor” that also served as an adapter from the 8mm outlet pipe on the faucet to the 1/2″ NPT fitting on the retractable hose assembly.  At Butch’s suggestion I shut off the bus fresh water pump, shut the valves on both the hot and cold supply lines that feed the kitchen sink faucet, and disconnected the supply lines from the inlet tubes that are part of the Kohler faucet.  I inserted the barbed end of the 1/2″ NPT adapter into a piece of rubber hose that I got from Butch and threaded the pipe thread into the cold supply line.  I placed the end of the hose in a bucket, turned on the pump, and then opened the cold supply valve.  I had lots of flow.  I closed the valve, shut off the pump, and repeated this for the hot supply which also had good flow.  That meant the problem was either in the restrictor, in the valve cartridge, or somewhere in the faucet body.  The good news was that the restriction was not in the upstream plumbing.

By mid-morning Butch was ready to make a parts run so I grabbed my short shopping list and rode into Logansport with him.  When we got back I disconnected the kitchen faucet hose from the restrictor/adapter and then disconnected the restrictor/adapter from the 8mm outlet tube.   The garbage disposal was in my way so I disconnected and removed it temporarily.  Initial inspection revealed that the restrictor was clogged so I started taking it apart and Butch finished the disassembly.  I reinstalled the adapter without the restrictor parts and tested the flow.  It was now very strong, which meant that the valve cartridge and valve body were OK and did not need to be serviced or replaced.  That was a good thing as we had not been able to remove the cartridge earlier when we tried.  With the water shut off I removed the flow restrictor/adapter cleaned out the entire assembly, and removed one small rubber O-ring.  I reassembled all of the pieces, turned the water on, and checked for leaks.  I did not see any so I turned off the water and cleaned up the area.

The Tarheel roof mount antenna lifter.

The Tarheel roof mount antenna lifter.

It was early afternoon by the time I finished the faucet project—too early to stop working on such a perfect weather day—so I started working on the wiring for the Magnum ME-ARC remote, which I want to relocate from the electrical bay to the house panel in the kitchen.  Because of the difficulty of running wires between these two locations I decided to follow John Palmer’s advice and re-purpose one of the two nine-conductor serial cables that connected the old Heart Interface EMS-2800 inverter/chargers to their remote panels in the house panel.

I decided to use the cable labeled #2.  I removed the snap-together Amphenol DB-9 connector from the house panel end and cut the molded DB-9 connector off of the inverter end.  I tried using Butch’s RJ-11 strip/crimp tool and discovered that the wire in the cable was one size too large to fit in the stripper so I stripped and trimmed them by hand.  The wires were stranded so I twisted them tightly but found that I could not get them inserted and lined up properly in the RJ-11 connectors I bought at Home Depot the other day.  Ugh.  Time for Plan B.

While we were working today plans got made for dinner at the Hibachi Grill Supreme Buffet in Kokomo, Indiana at 6:30 PM.  I decided to drive myself and leave early enough to go to Discount Tire in Kokomo and have them balance all four of my tires.  They closed at 6 PM so I stopped working around 3:30 PM, changed into cleaner clothes and headed for Kokomo at 4:15 PM.  Kokomo is about 30 miles south of Twelve Mile and takes about 45 minutes with speed limits and stop lights.  It used to be on US-31 but Indiana has made significant changes (improvements) to US-31 so that it is now a four lane divided limited access highway in many places and bypasses a lot of towns, including Kokomo.  What was US-31 is now SR-931.  Why they named it that instead of “Old US-31” as they have done in other spots is a mystery to me.

Before I got to Discount Tire I passed a Gordon Food Service (GFS) and a Menard’s located next to one another.  I needed things from both but wanted to get the car taken care of first.  Discount tire said it might be 90 to 105 minutes before they could get to me.  I could not wait that long but had them write it up anyway.  They took my car in about 25 minutes later and had it done in another 15 minutes, so I had time to do some quick shopping.

I got a package of 25 16 oz. hot cups at GFS to go with the lids we already had.  At Menard’s I got two surface mount 4-wire phone jacks and a double-ended phone cord for my Magnum inverter/remote project.  Butch and Fonda also stopped at Menard’s looking for dryer vents to use with their bathroom and shower ventilation fans.

Dinner at the Hibachi Grill Supreme Buffet was a family gathering.  Beside Butch and Fonda (and me) we had Butch’s mom and dad, his sister Robin and her mother-in-law Betty, Butch’s brother Tom and his wife Tracey, their son Brock and his wife, and another young couple and their kids.  I think the wife was Tom and Tracey’s daughter.  There were four or five kids whose names I did not get.  We all ate too much.  The food was OK, but Butch’s family and the conversation were more interesting.  It was 9 PM by the time we got back to Twelve Mile and I headed off to bed to take care of correspondence and writing.

2014/10/22 (W) Plan B

You always need to have a “Plan B,” or be prepared to come up with one on short notice.  Backup plans are not a sign of indecision or a lack of commitment to a primary plan.  Rather, they are an acknowledgement of the reality that things do not always work the way you thought they would no matter how brilliantly conceived, carefully planned, and skillfully executed.  So it was with my inverter/remote re-wiring project.

I spent most of the day working on the wiring that would allow me to move the Magnum ME-ARC remote from the electrical bay, where it was plugged directly into the Magnum MS4024 inverter/charger, to the house systems monitoring and control panel next to the refrigerator.  It was simple enough in concept, but I had to make sure it was correct as I did not want to damage the inverter or the remote unit.

I used four of the nine wires in one of the old serial cables (#2) that runs from the electrical bay to the house panel.  Since the phone line cables with the RJ-11 plugs on the ends used Black, Red, Green, and Yellow I decided to stick with those colors all the way through.  However, because of the way the RJ-11 connectors are assembled onto the cable the signals move back and forth between pins.  I ended up wiring the cable end in the electrical bay to the same color wires in the baseboard outlet and mounted it to the ceiling of the bay.  I cross-wired the other end of the cable to another baseboard outlet and mounted it to the side of the cavity behind the house system panel.  Fortunately the back side of the panel is accessible via a removable panel in the back of the closet that is on the other side of that wall.

With all of the wiring done I used a jumper with alligator clips on each end to bridge two of the wires in the electrical bay outlet and do a continuity check at the house panel outlet to verify the wiring.  Everything looked good so I unplugged the remote, brought it inside, and plugged it in.  It worked!  Now all I had to do was mount it.

There were already two cutouts at the bottom of the house systems panel from the old Heart Interface EMS-2800 remotes (the coach had two of these inverter/chargers when we bought it and each one had its own remote).  The cutouts measured 4.625″ W by 2.875″ H.  The housing on the ME-ARC was slightly wider than the opening but not as high.  Depth was not an issue.  I borrowed a small roto-tool from Butch with a small router bit and carefully opened up the left hand edge of the right hand cutout.  Using the remote as a template I marked the locations for the four corner screws, moved the remote out of the way, drilled out the holes, moved the remote back into position and attached it to the house panel using four #6 machine screws and Nylok nuts that I got from Butch.

The house systems panel with Magnum ME-ARC remote installed at lower right.

The house systems panel with Magnum ME-ARC remote installed at lower right.

While I was working on my project, I periodically asked Butch if he needed any assistance, but Fonda was providing the needed help.  They managed to mount an 18″ H by 24″ long piece of 3/4″ plywood to the back wall of the Oasis/water bay with a 1/4” heavy rubber separator between the wood and the metal.  Butch then mounted their Shur-Flo 4048 water pump to the plywood.  This should cut down considerably the noise and vibration transmitted from the pump to the structure of the bus and into the living quarters, but only experience will prove if that is the case.  Butch moved their fresh water tank slightly to make room for their portable water softener.  They also installed the two dryer vents, one on each side of their bus, which they picked up at Menard’s last night.  Their final project for the day was to cut a hole in the roof and install a right angle cable junction box that will be used to route coaxial cable and other lines from the roof into the passenger-side cabinet in the bedroom at the rear of their bus.

I looked at installing the remote readout for our Progressive Industries EMS-50 and decided it was more work than I wanted to start late in the day.  Butch suggested that I do it the same way I did the Magnum remote, re-purposing some of the wires in the old serial data cables.  That was going to require additional parts, so I started a list for my next trip to town.

My final project for the day was to try and fix the lighted entrance handle and the non-functioning patio light.  The lighted entrance handle had a badly deteriorated gasket behind the top securement so I fashioned a replacement from a piece of heavy vinyl shower pan liner that Butch and Fonda had.  The bulb was an LED I installed some time back.  It was still working but the socket was loose so I tried to squeeze it down a bit.  Butch pushed the spring loaded center section out, stretched the spring, and put it back in.  The bulb is now nice and tight.

The patio light proved to be more difficult.  The lens was cracked and difficult to get out but I finally did.  It’s a florescent fixture with two F8T5 bulbs.  I tried turning them in their lampholders but that did not help.  I pulled the wires far enough out of the wall to find two butt connectors.  I was able to get my multimeter probes far enough into one end of each connector to verify the presence of 13 VDC that was controlled by the same switch as the lighted door handle.  I removed the two bulbs and tested them in the fixture over the kitchen sink.  They both worked fine, so the problem appeared to be the ballast.

The way the fixture is designed there was no way to get to the ballast to replace it so I put the bulbs back in and got them to glow faintly.  I tried to replace the lens, which was already cracked, and the top inch split off all the way across.  Fonda though she could fix the cover and epoxied the two pieces back together.  While the epoxy was setting up I noticed that both lamps had come on full bright.  By the time Butch reinstalled the lens they had both gone out.  Definitely a bad ballast.

As it turned out, Butch had an almost identical brand new fixture that he did not intend to use.  The only difference was that his fixture had an on/off button on the underside whereas the one on our coach has a plastic plug in that hole.  His fixture has black end caps, which is fine, and is not painted to match the color of our coach, which is also fine.  Removing our current light fixture will be a bit of project and will have to wait until next week.

I ended up going to Logansport at 7:15 PM for a few parts that I would need tomorrow.  I got back around 8:30 PM and it took me 20 minutes to get my dinner ready and take it into the house.  I was straightening up the bus after dinner and looking for a new roll of paper towels for the kitchen when I discovered a mouse nest in the small cabinet between the sleeper/sofa and the kitchen base cabinets.  I put on nitrile gloves and cleaned it up and then inspected the compartment.  It was open at the back to the area above the HVAC chase that is part of the bus.  The more I have peaked in and under cabinets the more I have come to realize that our coach is a lot like Disney World; there is a network of passageways that are hidden from view but interconnect the bays with the areas behind and under cabinets and furniture, providing an subterranean road system for small critters.  It’s always something when it comes to bus conversions.  The long term challenge will be to figure how where the critters are getting in and see if we can plug those ports of entry.