Tag Archives: Twelve Mile IN

2016/4/16-20 (S–W) From Ham to Home (Again)

2016/04/16 (S) A Local Hamfest

I heard Butch and Fonda get in their car a little before 6 AM this morning and leave for the quad-county hamfest at the fairgrounds between Peru and Mexico (in North Central Indiana, not Central America).  I got up quietly at 7:30 AM, got dressed, put my camera in the car, and walked over to Small Town Brew to say “good morning” to proprietor Lisa Paul and fill my coffee thermos before driving to the hamfest.  As I approached the coffee shop I sensed that something was amiss.  The lights were off and something about the appearance looked different.  A closer view revealed that the interior had been redone and the name Small Town Brew was nowhere to be seen.  “The Branded Bean” was written on the window instead, but regardless of the name it clearly was not open for business.  I walked back to my car and drove to the hamfest about 10 miles away, slightly disappointed at not starting my morning with a nice cup of coffee and a cheery chat with Lisa.

There were quite a few cars parked around the venue when I arrived.  I’m not sure why, but hamfests and swap meets always seem to begin at sunrise and end by early afternoon.  Perhaps it’s a certain residual military influence or because it just leaves the rest of the day open to go home and play with new found treasurers.  Whatever the reason, I paid my $5 admission, got my door prize ticket, found Butch to say “good morning,” and then got some coffee.  Fonda was already taking her Amateur Radio Operator General Class license examination and Butch was busy with potential buyers so I walked the aisles in search of ham radio or other treasurers I could not live without, but did not find any.

Hamfests and swap meets are mostly cash only affairs unless there are larger commercial vendors there, in which case they might take credit cards.  I do not carry much cash, which is a good way to make sure I don’t spend much money buying junk I don’t need.  I did find a placemat size laminated grid square map of the United States for $5 and a laminated letter size sheet with the U.S. Amateur Radio frequency allocations for $1 and bought those.  Butch liked them so I went back and got a set for him too.  I also found some relays mounted to substantial heat sinks.  The seller had four of them for $1 each so I bought one without any specific purpose in mind.  The heat sink alone was worth more than $1 and Butch bought two of them later.

I eventually sat down at Butch’s tables and chatted with him (when he wasn’t busy) while we waited for Fonda to emerge from the testing room.  When she did she had a big grin on her face and we knew she had passed the test.  She only missed one question out of 35, which was an excellent performance.  Butch immediately got their W5YI / Gordon West General Class Study Guide and CDs out of a storage tub and put them out for sale.

Although Fonda had not studied for the Amateur Extra Class license exam she decided to take it since there was no additional testing fee beyond the $15 she had already paid to take the General Class test.  I decided to stick around and keep Butch company (not that he needed me to do that) until Fonda finished the Extra exam.  She got 19 items correct out of 50, not enough to pass but not bad for not having prepared, and it gave her a sense of what the test is like.  She wants to get her Amateur Extra license before the end of June as a new question pool goes into effect on July 1, 2016, and is very different from the current item pool.

I spent a few minutes talking to a soldier from the Indiana Army National Guard about the Hum-V they brought to the event and then returned to our rig in Twelve Mile.  I told Linda that Fonda had earned her General Class license (which Linda already has) and that Fonda was determined to get her Amateur Extra Class license by the end of June.  Not that Linda typically responds to a challenge, but this seems to have rekindled her interest in doing the same.

I had not eaten breakfast so we had vegan hot dogs and fresh fruit for lunch around noon.  I worked on blog posts until 1:30 PM when Butch and Fonda returned from the hamfest and I helped them unload their truck.  We all sat around chatting for a while but we were all very tired and Butch/Fonda needed to eat, so we returned to our motorhome to take naps.

Butch and Fonda had not reappeared by 5 PM so Linda checked to see if they were up as we wanted to go see the progress on their “new” house in Metea.  They were up so that is what we did.  We were at the house for over an hour looking at the interior reconstruction and discussing the plans for what was still to be done.  The house will not be ready to occupy this year and their hope/plan is to have it ready in 2017 before they leave again for the winter.

The property was seriously distressed but they got it for a good price.  Besides the house, which they are gutting and rebuilding inside, there is a 40′ W x 48′ L building with a concrete floor and two 12′ W x 16′ H overhead doors.  They could not build a new building like that for what they paid for the entire property.   We know, because we have been trying to figure out how to put up a similar building on our property.  Still, they bought themselves a big project and it is going to take some time and money to make it habitable and useable, or saleable if that is what they choose to do.

Fortunately they are now “retired” and still have the place in Twelve Mile to live as well as the converted bus.  Indeed, they still have an enormous amount of work to do to get the Twelve Mile property ready to sell.  It is an unusual property, having started life as a GM dealership in the 1930’s and only closing in 1981.  It then housed an electrical harness manufacturing operation before Butch and Fonda acquired it more than 20 years ago.  They turned the old showroom area into living quarters, retained the two bay auto service area for that use, as it has a functioning in-ground lift, and repurposed the rest of the space as a parts room, machine shop, wood shop, and warehouse for their business.

All told they have about 12,000 square feet under roof on two acres in the center of town on a state highway within very short walking distance of a bank and Post Office.  All-in-all, it has served their business and personal needs quite well over the last two decades but is now much more building than they need having sold off much of their business inventory in 2014 and closed Service Motors as an active supplier of parts for Crosley automobiles.  It will make an excellent building for someone, but it is going to have to be a buyer with specific and appropriate needs.

By the time we left it was 7:30 PM so we drove to the Mi Camino Real Mexican restaurant in Logansport for dinner.  Linda and I split a taco salad (no meat or dairy) and an order of vegetarian fajitas (no dairy).  We sat a long time after we were done eating just chatting before returning to Twelve Mile.  It was 9:45 PM by the time we got back so we called it a night and went our separate ways.

Back in our rig I checked my e-mail.  I had several from Gary at BCM, one of which had the first draft of the June 2016 issue.  My article on servicing the Webasto DBW2010.75 Diesel Burner is in that issue and needed to be proofread and corrections noted.  I made a first pass at that, replied to a couple of e-mails, and went to bed.  It had been a long but satisfying day and tomorrow was the first morning since this past Tuesday that we did not have to set an alarm and/or get up early.

2016/04/17 (N) Parts Shuffle

Fonda goes to church on Sundays.  She typically leaves around 9 AM and gets home between noon and 1 PM.  Butch is often up very early but not necessarily ready to interact with the world except through his computer so I tend to not bother him first thing in the morning.  We had a leisurely morning sitting around in our sweats (pants and shirts), enjoying our coffee, and eventually having breakfast.

When I finally got dressed and was in the humor to work, I unloaded the old tag axle caliper, old-old brake pads (not the ones I burned up), and the old torque plate, along with the new left-hand caliper rebuild kit, and moved them into Butch’s machine shop.  I also moved the old/broken Shur-Flo 4048 12 VDC water pump to his shop as he wants to see if he can figure out what failed and why.  With all of that stuff out of the car I repacked it to try and evenly distribute the weight of the remaining cargo.

Late morning I texted Jarel Beatty in Logansport to let him know we were here and invite him to come out and see the cabinetry he built for us last year as it was finally installed in the bus.  He had a shooting competition at 1 PM at the gun club/range near Twelve Mile and said he would try to stop by afterwards.

I had finally located the 24VDC regulator yesterday and showed Butch where it was located on our bus at the outside rear corner of the storage bay over the DS drive axle.  It was a very convenient location except that Royale Coach installed the slide out storage tray tight against the cover, making it impossible to remove without first removing the tray, which did not look easy to do.  Butch suggested that I unplug the chassis battery maintenance chargers, connect the batteries, and leave some of the bay lights on to draw off the surface charge so we could get a more accurate reading of the battery voltage later.  He also wanted to draw down the battery voltage a bit so that the alternator would have some work to do after starting the engine.

We were discussing how to deal with the failure of the regulator or alternator on the road and Butch suggested that I could always maintain the chassis battery voltage with a battery charger powered from the onboard genset.  I mentioned that besides the sophisticated, but low current, maintenance chargers that I have installed the coach came with a 24V emergency charger hardwired to the chassis batteries and powered from a 120 VAC outlet in the electrical bay.  The instructions for that charger, however, clearly indicate that it is for short time emergency charging to get the engine started and not for continuous use.  It given its age it is clearly not an “intelligent” multi-stage charger and would boil the electrolyte if left connected for too long.  Butch suggested that I remove the emergency charger and replace it with a modern, high amperage one that could be used to run the batteries and not just top them up for starting.  That seemed like a good idea to me so I added it to my (mental) project list.

Butch has been redoing the solar battery charging system on their bus and had one solar panel still to install.  Since it was loose he had me photograph the mounting rails he devised and attached to the long edges of the panel flanges.  The photos were for a future BCM article.

Jarel showed up sometime after 3 PM.  We showed him how we had installed all of the cabinetry and woodworking he had done for us based on my design drawings.  He had been in the bus several times before to discuss the project, so he had a good idea of what we were trying to accomplish, but visualizing it was one thing and seeing it quite another.  He really enjoyed seeing how the project turned out and took some photos with his phone to show his wife.

Linda started preparing dinner around 4:30 PM.  Jarel stayed and chatted until 5 PM and then went into Butch and Fonda’s house to visit with them and their dogs, Rascal (a Jack Russell Terrier), and Daffy (some kind of wire-haired Terrier mix thing).

While Jarel was visiting I borrowed a set of jumper cables from Butch and some sandpaper.  I used the sandpaper to clean the two terminals in the passenger side engine bay that are used to jump start the engine.  I then attached the jumper cables in such a way that the free ends could not touch, or the positive lead short to the chassis, by clamping the ground lead to a rail in the bay and setting the positive lead on a piece of cardboard on the ground.  I then clamped my VOM leads in the two jumper cable clamps so we would not have to hold them.

After Jarel left we checked the voltage on the battery bank.  It was 24.95 VDC.  A fully charged lead-acid battery bank at rest would be 25.2 VDC, so the voltage was reasonable given that I had the maintenance chargers off and there were some small loads on the system.  Butch had me start the bus motor, let the oil pressure come up, and then shut it off.  He had me start it a second time and then shut it off, and then start it a third time and leave it running, switching it to high idle.  While I was doing all of that he was monitoring the voltage on the VOM.

The voltage was showing just over 28 VDC, which is what we expected from a properly adjusted, correctly operating voltage regulator.  The voltage rose slightly when I switched the engine to low idle, but the batteries were probably fully charged by then and the current draw was probably minimal.  In any event it did not rise above 28.5 VDC, nowhere near the 30 VDC that would trigger a “high battery voltage” warning light on the dashboard.  There was also no indication of the alternator/regulator not producing adequate voltage as the “low battery voltage” warning light (the same light, actually) is triggered by a voltage below +24 VDC.

While the engine was running I made a mental note of the position of the needles on the two analog battery voltage gauges in the dashboard.  The “24V” gauge was higher than the 28V mark by a full needle width, i.e., there was a needle width gap between the 28V position and the left edge of the needle.  The gauge is only marked every 4 volts so it looked to me like it was reading around +29V.  The “12V” gauge was sitting right on the 14V mark.  The “24V” gauge should read 28 VDC and the “12V” gauge should read exactly 1/2 of that if the Vanner equalizers are working correctly.

Our simple test did not preclude intermittent problems with the alternator and/or voltage regulator that might occur after they were warmed up, and/or vibrating with the engine rotation at full RPM, and/or bouncing down the road.  It also did not rule out problems with the Vanner battery monitoring system, which is what controls the warning lights on the dashboard.  We also did not check the voltage at the battery bank center tap to see how closely it matched the gauge on the dashboard or how closely it was tracking 1/2 of the overall voltage as a check on the operation of the two Vanner Battery Equalizers.  Still, it appeared that the alternator and regulator were functioning correctly.

Linda made black beans and rice for our dinner and Fonda made baked squash and pork chops for their meal.  We also had carrots, grapes, strawberries, and pickled vegetables, including okra, to share around the table.  After dinner we got out our lawn chairs and sat outside for a while, pretending we were “camping.”  The air temperature dropped as the sun set and we finally put the chairs away and went inside the house to continue visiting as we had no way to make a campfire in their driveway.

By 10 PM we were all tired.  I asked Butch if I could use his big auto shop air-compressor in the morning to adjust our tires and he said he would turn it on and put the hose out first thing.  We returned to our coach and were fairly quickly off to bed.

2016/04/18 (M) Twelve Mile To Turkeyville

I was awake at 6 AM and finally got up at 6:30.  I put on my sweats, fed the cats, and prepared our morning coffee.  I noticed that Butch had already put the air hose out where I could use it so I checked/adjusted all of the tire pressures while the coffee brewed.  I also turned on the TireTraker TT-400 receiver/monitor and plugged in the repeater in the PS rear closet of the bus.  The outside air temperature was in the low 50’s F and all of the tire pressures were slightly below the cold pressures I like to run so I adjusted them.

After all of the tires were adjusted, and the air hose and tools were put away, I went inside the bus and used the monitor to check all of the tire pressures/temperatures and make a chart showing the actual and indicated values for each tire.  All of the sensors indicated pressures higher than the ones I had just set, using a known good digital tire gauge, by 1.0 to 4.5 PSI.  While this was within the specified “precision” of +/- 4% for the sensors, it was not as accurate as I think it should be.

Linda was up by this time but waited for me to have coffee and cereal (homemade granola) for breakfast at 9 AM.  Today is a travel day for us, and we would not normally have coffee or breakfast on a travel day, but we were not planning on leaving until around noon for the 3-1/2 hour drive to the Camp Turkeyville RV Resort near Marshall, Michigan.  We will also pass the Michigan Welcome Center / Rest Area and stop for fuel at the M-60 exit, so we will have opportunities to use facilities if needed.

After thinking about it overnight I decided that it did not make any sense for us to take the three new/rebuilt brake calipers home to Michigan only to have to haul them back to Indiana in a few weeks to have our mobile mechanic, Joe Cannarozzi, install them.  I borrowed one of Butch and Fonda’s hand trucks and move them from the car to the machine shop one at a time.  I then repacked the back of the car, which was now 300 to 350 pounds lighter than when we arrived in Twelve Mile.

Sometime between 9 and 10 AM I called Camp Turkeyville to make a reservation for today.  Angela was not in the office but a woman took our name and request.  The park was far from full and the reservation not really necessary, but we wanted to make sure we got a full-hookup pull-through site.  We visited for a while with Butch and Fonda before making our final departure preparations.  By 11:30 AM we were ready for the final steps in the departure process.  Linda moved the car from in front of the bus and battened down the inside of the bus while I got the shorepower disconnected.  I started the motor, let the chassis air up, and pulled it straight across the street into the grain elevator driveway where Linda pulled the car up behind it.  With the car connected and prepared for towing I restarted the bus engine and we did our light check.  Butch and Fonda walked over for one last, quick conversation and then it was time to go.  They never chat with us while we are hooking up as they know it can create a dangerous distraction.

We knew the exact route we planned to follow but entered the destination into the Rand-McNally GPS anyway.  Ever since I did the update at Florida Grande Motor Coach Resort the unit has been very sluggish in its response to screen taps but appears to still work.

I looped around through the grain elevator driveway back to IN-16 and headed east out of town.  At US-31 we headed north.  The GPS unit kept trying to get me to head east on county roads but I stayed on US-31 all the way to US-20.  At US-20 we headed east and stayed with that route all the way to I-69 in spite of the GPS unit’s repeated attempts to get me to turn north and head up into Michigan, presumably to pick up US-12.  At I-69 we headed north and soon enough we were back in our home state, the first time since November 27th last year.

About 12 miles into Michigan we stopped at the Welcome Center / Rest Area briefly and then continued or trip.  We exited again at Tekonsha / M-60 (exit 36?) and stopped at the Travel America for fuel.  The pump would not accept our Chase VISA card and we assumed that Chase Bank, ever vigilant with regards to its use as we cross state borders, had rejected it.  It turned out that the truck pumps were only set up to accept corporate/fleet cards so Linda had to go inside anyway and used one of our other cards to pay for the fuel.  All of this caused a bit of a delay but I eventually put 50 gallons in the tank.  I did not fill it because I did not want to put in the additives at this fuel stop.  I wanted to do that at the Mobil Truck Stop near our house and top it up just before getting home.

On our way once again we exited I-69 at N Drive North and a half mile to the west pulled into the entrance to Camp Turkeyville.  It was just before 4 PM and Angela was in the office and expecting us.  The site she planned to put us on had a car parked in it, without the owner around, so she moved us to a different one a few sites down.  It was a difference without a distinction and was an easy in, easy out, relatively level pull-through full-hookup site, which was all we cared about.  I adjusted the level and then shut off the motor.  The only hookup we needed for the rest of the day and evening was electricity so I took care of that and shut off the chassis batteries and air supply for the engine accessories.

Since we would only be here for one night we did not set up the interior the way we would if we were sticking around for even a few days.  We were parked facing south and the afternoon sun was bright and warm so I put out the awnings on the passenger side of the coach.  Gary, a fellow camper from a few sites down, stopped to chat and compliment us on our motorcoach.  After we wrapped up our chat we went inside and had an easy dinner.

One of our routines (traditions, rituals?) is to walk an RV park when we arrive unless the weather is very disagreeable.  The weather was near perfect this afternoon, and it was still plenty light at 7 PM, so we walked over to the Cornwall’s Turkeyville building to see if it was still open.  The building houses a restaurant, ice cream parlor, and general store.  They were open until 8 PM so we meandered through the store but did not buy anything as neither of us brought our wallets.  We strolled back to the campground and walked the outer loop before returning to our coach.

We had access to quite a few OTA TV signals and tuned in one of the CBS affiliates with a strong signal.  We watched our usual Monday evening TV programs and turned in for the night without setting an alarm.

2016/04/19 (T) Home Again

With the overnight low outside air temperature forecast to be in the upper 40’s we left the bathroom roof vent and bedroom windows open as we knew the outside conditions would make for wonderful sleeping conditions inside the coach.  We were tired, and did not have to be up at any particular time, all of which made for good sleeping snuggled under a thin blanket.  I got up at 8 AM, tended to the cats’ needs, and made 7 cups of coffee.  A little after 9 AM we had toast and preserves for breakfast.  We don’t usually have breakfast and coffee on a travel day, but today was the final leg of our winter 2015-16 snowbird season, and the trip from Camp Turkeyville to our home was only 80 miles, with rest stop opportunities along the way if needed.

Checkout time at Camp Turkeyville RV Resort is noon and our target was to pull out between 11:30 AM and noon.  Part of the reason for stopping here for one night before going home was to empty our waste tanks.  Another reason was to give us a short, easy drive at a time of day that avoided the rush hour traffic at the beginning and end of the work day.  This was the third year in a row that we have done this and it works very well.

We started tending to our departure tasks around 10 AM and would have been ready to go by 11 AM except for a very nice, but very talkative, neighbor.  Still, we were on schedule and not in any particular hurry.  We pulled out of our site at 11:30 AM and made the long, slow trip around the outer road of the campground to get back to the exit.  Once we were on I-69 N I set the cruise control at 63 MPH and let the bus roll.  I-69 between I-94 and I-96 is a concrete road made of small, discrete slabs, and you feel every joint between them.  But hey, it’s Michigan; we expect the roads to be in bad shape and we like it that way (not).  Well, apparently the majority of our fellow citizens like it that way, OR at least prefer it to paying taxes and enforcing weight limits and speeds.  If that wasn’t the case, our elected officials would do something about it.

There was rain headed our way but it was not expected until tomorrow or later.  Still, the sky was overcast and we had not traveled very far up I-69 when we started getting a light, intermittent drizzle.  It stayed with us all the way to Lansing where we picked up I-96 E.  By the time we got to exit 122 (M-52), where we stopped at the Mobil Truck Stop for fuel, we had driven out from under the rain.

Since the bus would be sitting for at least a couple of weeks I added Stanadyne Performance and Lubricity Formulas, and Racor Biocide before filling the tank.  It’s always better to have fresh diesel fuel but it is also good to store the bus with a full tank to prevent condensation from moist air in the tank.  My solution has been to use the Biocide and store the bus with a full tank.  If it is going to sit for any length of time I run the Parker Fuel Polishing Module to slowly filter it and remove residual moisture.

From the Mobil Truck Stop it was only 11 miles to exit 133 (M-59), another 10 miles to Hacker Road, and about 2-1/2 miles (on dirt roads) to our house.  This stretch of Hacker is scheduled for paving this year and we knew from the Livingston County Road Commission that work had already begun.  Indeed, the surveyors were working in the fall before we left for Florida.

The initial work this spring was the removal of trees along both sides of the road and as soon as we turned off of M-59 onto Hacker it was immediately obvious that this had occurred.  It was also obvious that the road had been very recently graded and that there had not been any rain since then.  We still took our time, keeping our speed to about 25 MPH, but it was one of the smoothest trips we have ever had in the bus along this stretch of Hacker.  To our delight, the grader had also obviously done our street recently and we noticed that a few of our neighbor’s had apparently trimmed or removed a lot of trees and bushes near the road.  Yeah!

As we got to the first of our three driveway entrances I stopped the coach and lifted the tag axle while Linda got out.  She always spots for clearance to obstructions and guides me into the final parking position.  There were a few larger tree limbs in the driveway so she picked those up before I pulled in.  Once I was positioned on the level parking pad area of the driveway I put the tag axle down.  The coach was close enough to level that I did not bother adjusting the suspension.  After letting it idle for a couple of minutes I shut off the motor and we started our arrival routine with one notable difference; Linda’s first task was to get the cats in their carriers, unlock the house, take them inside, and let them out of their carriers.  Coming home us a big deal for them, too.

I turned off the engine accessories air supply and the chassis batteries and connected the shorepower cord.  The circuit breaker for this electrical service is in the sub-panel in my office.  I turned on the wrong breaker the first time so it took a second trip to the basement of the house to get power to the coach.  We had no intention of unloading everything today but there were a few things we wanted to get into the house right away, such as wallets and keys.  At the top of my list was all of our computer, networking, and photography technology while Linda’s focus was on clothing and food.

Once we had our highest priority items moved into the house I texted the small circle of friends who we have been keeping in touch with about Linda’s illness and our bus problems to let them know we were home safe and sound with no further problems.  I then went to the garage, found our good battery charger, and connected it to the 12V starting battery in the Honda Civic Hybrid.  Brendan had told us a week or so ago that the battery was dead and when I connected the charger it would only accept about 2.5 Amps of current and quickly tapered off to less than one Amp.  That wasn’t much current for a depleted battery but I left it and went back into the house.

I checked a little while later and the charger had given up and displayed an “F01” error code.  I did not even bother looking it up as the car is a 2007 model and this was probably the original battery.  I decided to go ahead and get a new battery from O’Reilly’s in Howell, but first we had to unhook the Honda Element from the bus.  The car was filthy, having been towed at least 1,500 miles since it was last washed, but I stopped and got the new battery first and then went to the car wash just down the street on the same side of Grand River Avenue.  I then went to the Meijer’s supermarket at Grand River Avenue and Latson Road and picked up a few things.

Linda started preparing dinner at 5:30 PM and was just about to put the pizza in the oven when Butch called.  We chatted for about 15 minutes and he updated me on the removal of the radiator blowers and T-drive from their MCI MC-9 NJT bus.  This assembly is above the engine and almost the width of the bus but they were able to get it out using their forklift.  (It really is nice to have the right tools for the job.)  Butch noticed last weekend that a lot of the oil had leaked out of the T-drive and figured it needed new shaft seals, at a minimum, and might need new bearings.  With the assembly out of the bus Butch can conveniently do all of the needed work on a bench and repair/rebuild some other things while he is at it.

Our first dinner course was a nice salad with arugula and Italian kale.  The pizza was one of our favorites, an Amy’s Roasted Vegetables with Caramelized Onions.  By the time we were done eating it was almost time for our Tuesday evening CBS TV shows and I decided to replace the car battery tomorrow morning.  I did, however, move the NAS and my computer to my office and connect them to power and the Netgear switch.  To my great relief, the network interfaces on both devices still worked just fine.  Clearly, the Amped|Wireles SR20000G wired network ports had failed although I still do not know why and probably never will.

The 2015-16 TV season is coming to an end so the season finales are now airing and they are all cliffhangers, of course.  We went to bed at 11 PM, watched a rerun of Two and a Half Men, and a few minutes of The Late Show with Stephen Colbert before going to sleep.

2016/04/20 (W) Core Return

We love our bus, love being in the bus, and love the lifestyle the bus affords us.  But we are not true gypsies at heart, and we also love our house and property.  We like the anticipation of travel and the promise of new experiences, but we also like the comfort and stability of finally landing at home after a long voyage.

We slept in this morning and finally got up at 8 AM.  Some things are the same regardless of whether we are at home or in the bus, and morning coffee is one of them.  We were enjoying our morning brew when our son texted Linda to see if we were available to FaceTime.  Of course we were!  A short time later we were “face-to-face” with grand-daughter Madeline (and her parents).

Another constant is Linda’s homemade granola.  She managed to make enough of it, and/or we managed to limit our consumption of it sufficiently over the winter, that we still had some left for breakfast this morning.  We might have one or two more servings beyond today, but she will be shopping for ingredients and making a new batch very soon.  She will also be making sure we have the necessary ingredients on hand to make vegan pancakes and vegan cupcakes as we anticipate an overnight visit with Madeline in the very near future.

After breakfast we got dressed and got to work.  Linda called Alchin’s to restart our weekly trash pickup while I made a service appointment for the Honda Element.  We checked our home phone messages.  Only a handful of the 42 messages contained any actionable information.  I made note of those details and then deleted all of them.  I called Catamaran Home Delivery and ordered refills for two prescriptions.  I then called Keith at Kish Lawn Care to see when he was planning on starting our mowing this season.  Keith’s wife just had major surgery, and the grass has not grown much yet this spring, so the first cutting is probably still a couple of weeks away.

With our calls taken care of we turned our attention to replacing the 12V battery in Linda’s Honda Civic Hybrid.  The nuts on the two threaded hold down rods were badly rusted and did not want to come loose so I sprayed them with WD-40 and let them sit for a while.  I eventually got the nuts broken loose and backed off enough to remove the rods, but bent the retaining brackets in the process.  I put the rods in my bench vise, and finished removing the nuts.  We removed the old battery, transferred the anti-corrosion pads to the new battery, set it in place, and reinstalled the protective plastic 2-piece cover.  We connected the vehicle cables and then connected the good battery charger to it to bring it to full charge before trying to start the car.

Back in the house Linda unloaded containers of water from the house refrigerator and then wiped it out.  She then unloaded a few more things from the bus, including clothes and food.  I texted Jim and Kristine Gullen to let them know we were back and then started researching small tractors and mobile Wi-Fi devices.  Linda was getting ready to order an Instant Pot and a couple of 12VDC power adapters for our Rand-McNally GPS unit through Amazon and I suggested she look for the Burton portable induction cooker that we saw at Butch and Fonda’s place.  The Suntunpen unit we have now works fine but the Burton unit has two advantages over it; a completely flat/smooth top and higher maximum power setting.  She found it, added it to the cart, and placed the order.

Linda heated a can of Amy’s vegetable soup and we split it for lunch.  I checked the battery charger and it said the battery was full so I put the old battery on the back seat floor and had Linda start the car.  It started on the second try and she backed it out of the garage so I could get in.  The hybrid battery was depleted and there was a red battery symbol illuminated on the instrument panel that we had never seen before so we got the Owner’s Manual out and looked it up.  It either meant that the 12V battery was not charging or that the hybrid battery was drained below some threshold, or possibly both.  We could see the charge level coming up on the hybrid battery so we waited and the battery warning light eventually turned off.  Linda also noticed that the in-dash navigation system, having completely lost power, was requesting a security code to reactivity it.  I found the code on a sticker inside the glove box and after Linda entered it the system returned to normal operation.  When the hybrid battery charge indicator was above 50% she backed out of the driveway and we went on our errand run.

I was on Golf Club Road last night when I went to O’Reilly’s to get the new battery so I knew it was in rougher shape than usual.  We took Hacker Road south instead which kept us on pavement.  We headed back west on Grand River Avenue to O’Reilly’s to return the old battery and get the core charge refund.  We then drove back east a short way to the drive-through car wash.  Linda had not used it before and was unclear about its location.  With the car all cleaned off we headed west again to Teeko’s Coffee and Tea to order some fresh roasted coffee beans.  Jeff was there and roasted the beans while waited and enjoyed a cup of Sumatra Manhelding coffee.  We got our usual Ethiopian Yirgacheffe half-caffe blend and decided to try a Costa Rican Terrazzu half-caffe blend.

We took the long way home, going back east on Grand River Avenue and then north on Hacker.  The extra driving around gave the hybrid battery plenty of time to recharge and cycle up and down and kept our just-cleaned car mostly on paved roads.

Back at the house I backed my car up to the large garage door and unloaded everything inside in preparation for my 10 AM service appointment tomorrow at Brighton Honda.  While I did that Linda unloaded a few more things from the bus.  We had quite a few rocks on the concrete driveway, as a result of Kerry Fear plowing snow this past winter, so I swept them off with a push broom.  We also had 6″ high ‘curbs’ at our three driveway entrances as a result of recent road grading, so I graded them out using a metal toothed rake.

By the time we finished those tasks we were ready to be done with physical work for the day.  Linda decided to spend an hour or so studying the item pool for the ham radio Amateur Extra class license exam.  I gathered up the laundry, took it to the laundry room, sorted it, and started a load.  I then joined her on the back deck to work on blog posts for a while.  By 4:30 PM it was a little chilly and we went inside.  I took up my usual spot on one of the living room sofas and almost immediately Juniper (our female cat) was in my lap.

For dinner Linda made a nice salad with arugula, Italian kale, strawberries, and slivered almonds.  The main course was pan-seared tofu with caramelized onions and barbecue sauce, served with a side of corn kernels.  Yum.  After dinner Linda wanted to go for a walk so we patrolled our street from one end to the other, which took about an hour.

Wednesday night is usually PBS night for TV but neither of us were in a TV watching mood.  I went to my office for a while, checked in to RVillage, and changed our location.  I then went to the WiFi Ranger website, downloaded some manuals, and opened a support ticket.  Back upstairs I texted Joe Cannarozzi, our mobile mechanic, to arrange a time to call him and discuss brake work.  I then called Mike (W8XH) to catch up on ham radio and SLAARC stuff and check on borrowing his trailer to transport our non-functional Cub Cadet Lawn tractor to Sloan’s for repair.  By the time I wrapped up my conversation with Mike, Linda had gone to bed and was watching a program on PBS about a previous live broadcast from the Monterey Bay Marine Sanctuary called The Best of Big Blue Live.  Linda fell asleep but I stayed up long enough to watch a rerun of Two and a Half Men and the first half hour of The Late Show with Stephen Colbert while working on this post.  With the stroke of midnight came sleep.

 

2016/04/11–15 (M–F) Water Pumps on the Road Again

2016/04/11 (M) Parts Run

I was up at 7:30 AM, so I slept over seven hours last night, and felt like I had slept well enough to take on the day I had ahead of me.  I fed the cars, put fresh water in their bowl, and cleaned their litter tray.  I also cleaned part of the shower as one of them has developed loose stools in the last couple of days and has not always made it to the tray in time.  I moved the SunPass transponder, Garmin GPS, and my sunglasses to the car in preparation for my trip today.  By the time I had done all those chores Linda was up and both used our iPads for a while.  I was not going to make coffee this morning since I had a long drive ahead of me sometime today, but Linda wanted some so I made it and had some myself.  We eventually had bagels for breakfast.

I called Action Mobile around 9 AM and talked to Service Manager John Provo.  He expected my three brake calipers to be delivered between 10 AM and noon but that was just a guess on his part.  Rather than make an issue of getting a more accurate ETA I decided I would leave at 10 AM for the two hour drive from Williston to Orlando.  I went out after breakfast and unloaded most of the stuff in the back of the car and stored it on the picnic table.  I then walked to the resort office to let them know we were expecting a package from Amazon today.

Just before 10 AM I wrote out a short grocery list as I planned to stop on my way back from Orlando at The Publix supermarket on US-27 by the Ocala exit (#354) of I-75.  I took my iPad in case I needed to kill some time at Action Mobile, and actually left a little after 10 AM.

The trip down was smooth, with no traffic issues, and it was uneventful except for a text message from my sister asking me to call our broker and transfer funds for our dad.  Based on when I received it the best I could do was pull into one the Florida Turnpike Service Areas closest to Orlando’s northwest corner and call the brokerage.  The person I needed to speak to (Maggie) was on another call and I did not want to deal with a return call while driving so I left a message that I would call again when I got to my destination, which was still 20 minutes away barring any unforeseen traffic problems.

Traffic was thicker and a little slower as I neared Orlando but it moved along well enough and I reached Action Mobile just after noon.  I called Maggie again and got her this time as she is in the Central Time Zone.  Maggie is our broker’s office manager and is also a registered agent.  We have an extremely good relationship with her and our broker, John, so we chatted briefly before I gave her the transaction details.  I then texted my sister back to let her know I had taken care of her request.

I went inside and found John P. (the Service Manager).  The parts were not there yet so he called Rex at Rush Trucking to check on them.  Rex said they should have been there and made a call.  Not too long after that a white can showed up and the driver unloaded three Meritor boxes of the right size, shape, and apparent weight, and took off.

It occurred to me that I should check the parts before paying the balance and taking off myself so I opened all three boxes.  I was expecting one of the castings to have an “L” in the casting number and the other two to have an “R” in the casting number, but all three had “L”s and that caused me some concern.  I also noticed that one of the calipers had both grease fittings broken.  John P. called Rex back and Rex explained the Left and Right calipers used the same (“L”) casting.  The difference was in the helical drive shaft and gear inside, and difference was reflected in the part number on the box label.  The left side caliper part number began with “A 1” while the right side caliper began with “A 2.”   (The shaft for the calipers on the left side of the bus rotate clockwise, as viewed from the end where the slack adjuster attaches, while the calipers for the right side rotate counterclockwise.)

Rather than have Action Mobile remove and replace the damaged grease fittings Rex had a different left caliper sent over as he did not want to risk a small piece of debris falling inside the mechanism.  When the driver dropped it off I checked the label and the grease fittings.  There were OK, so he put the damaged one in his van and left.

While I was waiting I called Butch and gave him the information on how the left and right calipers were labeled.  He is working with someone at ABC Bus in Muncie, Indiana, who is working with someone at Rockwell-Meritor, who says we can still get these parts with a 45 to 60 day lead time.  I’m guessing that these are also rebuilt/remanufactured calipers, not new ones, but at this point in time we don’t really know.  He was quoted a price that was $200 less per caliper than I paid, but I have mine now, not two months from now; if in fact I could get them.

Bill, the mechanic who fixed our left tag axle brake last week, was taking his lunch break so we got to chat a bit.  John D. (the owner) was also around so we also got to chat for a little while.  I was running behind the schedule I had hoped to keep, so I loaded the three boxes into my car and went inside to pay the balance of the bill.  A quick chat with the billing clerk, Lisa, and I was on my way back to Williston.  It was 1:30 PM and I figured I would be back by 4 PM, including my stop at Publix.

I stopped at the Florida’s Turnpike Turkey Lake Service Area for some lunch but just ended up getting a frozen coffee thing at Dunkin Donuts.  Traffic moved along nicely all the way onto northbound I-75.  I had just passed exit 341 and was just 13 miles short of exit 354, when traffic came to a complete standstill.  The backup stretched as far as I could see in front of me and the flurry of emergency response vehicles driving up both shoulders meant there had been a serious accident somewhere up ahead.

It took at least an hour to reach the accident scene, where police had closed all three lanes of the highway.  All of that of traffic, which included two lanes of nose-to-tail tractor-trailers, had to funnel onto the right shoulder to get around the blockage.  The accident looked really bad and appeared to have involved at least a motorcycle, a large Suburban-like vehicle, and a utility trailer.  There may have been other vehicles involved that I did not see as I drove past or that had already been moved, although I doubted that.  There was no sign of the people involved and I presume they had already been transported from the scene by ambulances or helicopters.

Once I was past the accident I had clear sailing the rest of the way, but from the accident scene north the southbound lanes of I-75 were also completely stopped.  There were also emergency vehicles on the southbound side of the highway, but it did not appear that any of the accident was over there.  I exited I-75 at exit 354 (Ocala, Williston), made a left onto US-27, and pulled into the strip mall on the right where the Publix supermarket is located.

I took my short list of grocery items and went in.  In an unusual move for me I found everything on my list except for one item and did not buy anything that wasn’t on my list.  The only thing I could not get was fresh blueberries, which is odd because just today I had seen billboards advertising the Florida Blueberry Festival as running from April 11 – 16 in a town nearby.  Maybe all of the available blueberries were being routed to the festival?

I was back at our rig around 5:10 PM.  After getting the groceries inside, I turned my attention to reloading the car.  My first task was to transfer the new (to me) A1/Left caliper to the box the DS tag axle caliper came in last week as the box the new caliper came in was in very bad condition.  Linda found our roll of bubble wrap under the bed and I used pieces to protect the grease fittings on the top of each of the three new (to me) calipers.  (I say “new (to me)” because I believe the four calipers I have purchased are all rebuilt, and possibly even remanufactured.)

With that taken care of, I moved a couple of low boxes from the picnic table to the car and put them on the floor behind the two calipers that were behind the driver’s seat.  I then moved the tire covers from the front passenger seat and put them on top of the boxes.  The covers are a soft nylon mesh material which I figured would provide additional protection for the grease fittings.

We disassembled the damaged box to get flat cardboard pieces to use as a cushioning layer on top of the two caliper boxes that I had put inside the wooden storage structure.  The reason for all of this was that I had to store other boxes on top of the caliper boxes and, having received one that had damaged grease fittings, wanted to make sure I was not responsible for causing similar damage.  I had already taken the precaution yesterday of moving heavier items to the front bay of the bus, leaving lighter items for the car.

With the car repacked I opened the box from Amazon, which Linda said arrived around 10:30 AM, to verify that it was the correct Shur-Flo 4048 fresh water pump.  It was the correct box so I left it at that and we went for a long, slow walk around the resort.  When we concluded our walk we sat outside for a while and doodled on our iPads.  John and Ali returned around 6:30 PM.  As we suspected, they had gone out to dinner.  We presumed they had gone to The Blue Highway, but they had gone to The Olive Garden in Gainesville instead.

For dinner Linda made sandwiches with vegan deli slices and lots of greens, kind of like a salad on a bun, and sliced up a Honey Crisp apple.  It was a simple, easy meal, but it was all good.  As the hour approached 8 PM and the light faded we went next door to visit with John and Ali.  Earlier in the day John had taken one of his propane tanks over to be refilled but the person responsible for that task had not taken care of it.  When he tried to light the propane firepit it would not ignite.  We could smell the gas, and hear the spark, but if the tank was near empty it probably did not have enough pressure to make it work.  No problem; the conversation, if not the “mood,” was just as good without the fire.

It was a warm, still evening and there were more bugs out than the last few nights.  Everyone was tired by 10 PM and we all retired to our own rigs.  We watched the end of NCIS-LA and the beginning of the news and then went to bed.  I watched the beginning of The Late Show with Stephen Colbert to see Steve Martin and Edie Brickel, and then went to sleep.  Although I had not really done very much it had been another long, and somewhat stressful, day.

2016/04/12 (T) Water Pump Up

I got up at 7:30 AM and quietly took care of the cats’ food, water, and litter tray.  I measured out the beans for our morning coffee but waited to grind them until Linda was up.  I updated my spreadsheet for GLCC parking at the upcoming FMCA GLAMARAMA16 rally in June and then continued working on my blog post for yesterday.  When Linda got up at 8 AM I finished making the coffee.  We then spent a couple of hours engaged in our usual morning routine of using our iPads while enjoying our coffee and having granola with fresh strawberries for breakfast.

By 10 AM we were dressed and I got to work replacing the fresh water pump.  The pump is a Shur-Flo 4048-153-E75.  It is a 4 GPM (max), 55 PSI (max), self-priming, 12 VDC pump with thermal overload protection and the ability to run dry without damage (although our friends, Butch and Fonda, discovered that it cannot do this for an extended period of time).  Shurflo also makes this pump in 24 VDC and 120 VAC versions.  I am seriously considering adding a 120 VAC pump to the water system when I redo the utility bay, but I would like something a bit more robust.  I seem to recall that Chuck has a Paragon AC powered pump in their Liberty conversion and it impressed me as a very serious piece of equipment.

Since the new water pump was an exact replacement for the failed one installation was very straightforward.  I shut off the incoming fresh water line as a precaution and had Linda make sure the pump power was switched off.  I then disconnected the two power leads which I had wired using mating insulated spade connectors.  There are two fresh water supply lines, each of which gas a 1/4 turn shutoff valve, so I closed those.  (The conversion had two domestic water pumps plumbed in parallel when we first bought it.  I replaced them with a single 4048 and removed the surge tank at that time as Shur-Flo recommended not using one with the 4048 pump.)  The threaded water line connections to the pump are plastic and only hand tightened, so were dealt with easily.  Before removing them I got a towel to absorb the water that was inevitably going to drain out of the lines.  Once the lines were off I removed the four screws that secured the unit to the floor through the rubber shock mounts.  The unit was now completely disconnected and I was able to remove it.

The new and old water pumps along with tool boxes and other stuff needed to make the repair.

Installing the new unit was basically a matter of reversing the steps just described, more or less.  I  needed to attach the proper insulated spade connectors to the power wires on the new pump.  I found my spade lug kit and even though I had a variety of connectors I did not have the ones I needed.  Fortunately there is a NAPA Auto Parts Store very close to Williston Crossings RV Resort and auto parts stores are an excellent place to find a large variety of spade connectors.  It’s walking distance to the store, but I drove there to save time.  I bought several different packs to make sure I had what I needed.

Back at the bus I prepared the power leads and set the new unit in place.  I connected the water lines first as it was easier with the unit loose.  I connected the power leads and then screwed the unit to the floor.  The new pump came with a strainer and adapter fittings.  I used the new strainer bowl to replace the old one, in which I found little curly queues of plastic.  I opened the two shutoff valves and then had Linda turn on the power to the pump and open the kitchen faucet so that both the hot and cold lines were open.  The unit came to life and water flowed, albeit with a sputter until all of the air was out of the lines.  With that, the water pump problem was fixed and I cleaned up the work area and put my tools away.

Next on my task list was checking tire pressures.  I really did not want to check all 12 tires with the digital gauge so I turned on the TireTraker TT-400 TPMS and waited 20 minutes for the readings to update.  Although the sensors are not “dead on” accurate they are close enough to let me know if a tire has lost enough air to require topping up.  They all appeared to be OK so I did not have to get out the air-compressor and air hose.

Barring any further unforeseen circumstances this was our last planned night in Florida for the 2015-16 winter season.  We wanted to go to Satchel’s in Gainesville for pizza one last time.  We decided to have an early dinner and take care of a couple of errands so we left at 2 PM.  Our first stop was at the Kangaroo filling station for gasoline.  Our next stop was Pet Supplies Plus in the Archer Road mega strip mall shopping complex.  We also stopped at the CVS pharmacy in the same complex and then drove to Satchel’s on the east side of town.

Although it was a lovely afternoon, weather wise, we chose to sit inside.  At Satchel’s we had our usual meal; an excellent salad and a pizza with mushroom, onion, sun-dried tomato, and Daiya non-dairy cheese.  It is, quite simply, one of the three or four best pizzas we have ever had, and it is vegan!  We got their largest pie and brought most of it home.

When we got back to Williston Crossings John and Ali were not around and we figured they had gone out to dinner again.  Happy hour usually takes place at Jeff and Kathy’s 5th wheel so we walked down there to visit for a while.  John and Ali eventually returned and as evening fell over the resort we went next door to sit around their propane campfire and visit.  Smitty made a large bowl of popcorn popped in peanut oil and lightly salted with Hawaiian sea salt.  Yum. Note for T 20160412 blog post.  Jim and Janet Rawley came over to John and Ali’s site to visit and John played his guitar and sang for a while.  Jim’s professional name is “Sonny Fox” and he was a big time rock ‘n roll D. J. during the ear when radio stations started playing “album rock.”  Jim quizzed me about my musical background and the first record (45 or LP) that I bought but I had no recollection of that.

We returned to our rig just before 10 PM and were in bed, with the lights out, by 10:30 as we planned to pull out of our site around 7 AM in the morning.  Tomorrow we head north and leave Florida.

2016/04/13 (W) Unbalanced Travel

I set an alarm for 6:20 AM and we got up at 6:30 and got dressed.  Today was a travel day so we did not have coffee or breakfast.  While we prepared the interior of the coach for travel I encountered a problem with the 12 VDC charging plug for the Rand McNally TripMaker RVND 7710 GPS unit.  A small threaded plastic insert, which holds the spring-loaded +12V center contact, had broken and could not be repaired on short notice (if at all).  The two lower 12 VDC “cigarette lighter” outlets were dead again and it occurred to me that the failed plug might have been responsible for shorting the outlet and blowing the supply fuse last Wednesday.  Not realizing this at the time, and desperate to get the GPS back into service, I vaguely recall having plugged it into one of the upper outlets and probably shorted it out too.  I replaced all of the blown fuses last Wednesday but did not realize at that time what the root cause was and was rather perplexed by the failure, which reoccurred on the lower pair of outlets.

I removed the R-M GPS from its usual mounting position (on the driver side lower windshield next to the center pillar and resting on the top of the dashboard cover) and set it aside and I installed the Garmin 465T GPS unit in its place.  I took care of the remaining outside tasks of disconnecting/storing the shorepower cord, connecting the chassis batteries, and opening the auxiliary air supply valve for the engine accessories.  Linda moved the car to another site so it was out of the way as I started the bus motor and aired up the chassis (brakes and suspension).  She then spotted for clearance from obstructions as I slowly and carefully pulled out of our site.

We wanted to be on the road at 7 AM but it was about 10 minutes past the hour when I finally pulled out of the site.  Our friend and neighbor, John (Smitty) Smith, was up and outside to wave goodbye, which was nice.  I proceeded north through the resort on Covered Bridge Road and Linda followed in the car.  We drove through the covered bridge, for which the road is named, and stopped just short of the north bath/laundry building to hook up the car for towing.  There are no park model trailers or RV sites close to this location, so we knew we could hookup here without bothering anyone.  With the car attached we double checked the settings and then did our light check.  Everything was OK so Linda got into the coach and we set our destination in the Garmin GPS unit.

We finished our slow roll through the RV resort, out the back/northwest gate, and pulled out onto FL-121 headed northeast towards Gainesville.  About two miles from I-75 we encountered stop-n-go traffic.  The morning rush hour in Gainesville was underway and was something we had not previously experienced.

Linda kept a close eye on our tire pressures and temperatures, especially the driver side tag axle, as we rolled along.  We stopped at the Pilot station at Exit 460 and took on 60 gallons of diesel fuel.  That was our last stop until we got to the end of our trip for the day.  I would have liked to note here that the trip was uneventful but, alas, that was not the case.

The drive up I-75 through northern Florida and southern Georgia is generally an easy one, without any serious grades to climb or descend, attractive enough scenery, and reasonable traffic volumes except during the April 1st northward snowboard migration.  As we got to the Macon, Georgia area and then on up to Atlanta, traffic was heavier but moved along.  Somewhere along the way the Battery Balance (BAL) light came on, flickering at first but then staying on.  Not good.

The Battery Balance light is controlled by a Vanner Battery Monitor Module and is supposed to indicate that the “12V” center tap on the battery bank is not within +/- 0.75 VDC of 1/2 of the voltage between the “24V” terminal and ground.  The relationship of these voltages is supposed to be regulated by a pair of Vanner Voltmaster Battery Equalizers.  It is normal for this light to come on occasionally, especially when starting the motor, but it is not normal for it to come on and stay on.  Assuming the monitor module is not defective, it means the 12V center tap is out of tolerance with respect to the 24V terminal and implies that the Vanner equalizers are not doing their job.  Ugh.

Having the yellow Battery Balance (caution) light come on immediately added stress to the trip but when the red Hi/Low Battery (warning) light came on the stress level went way up.  This light is also controlled by the Vanner Battery Monitor Module and is (supposed to be) activated if the voltage at the “24V” terminal (relative to ground) is less than 24V or more than 30V.  Voltages outside the 24 – 30 VDC range could indicate a malfunction of the voltage regulator and/or engine-mounted alternator.  Either one would be a problem that could put the bus on the side of the road as the engine is controlled by a computer that is powered by the chassis battery 12 V center tap.

The normal full-charge resting voltage of a “24V” lead-acid battery is 25.2 VDC (12 cells in series at 2.1 volts per cell) and the normal voltage at the 24V terminal with the motor running is around 28 VDC, so the 24 – 30 VDC range is a reasonable one. I also have 24V and 12V analog battery voltage gauges in the dashboard that are connected to the batteries independent of the Vanner Battery Voltage Monitor Module.  While they would also show high or low voltage conditions, and, by comparison, a battery imbalance condition, it is appropriate to have warning lights to get your immediate attention as you might not notice the gauges for a while.  What was odd about this situation was that the 24V gauge was sitting at about the 29V position and the 12V gauge was sitting at about the 14V position.  I knew these gauges worked because they do not always show these readings, but I did not know if the readings were accurate.  They are, however, close to what I normally see, and they do not usually result in caution or warning lights.

We left I-75 (GA) at exit 296, Cassville-White Road, drove 0.2 miles east to the Pilot truck stop, and got in a long to wait for a pump.  When it was finally our turn I added 92 gallons of diesel fuel.  From the truck stop we drove west back towards I-75 and continued 0.5 miles on the other side of the highway before turning left into the Cartersville Castle-White KOA.  Linda was hearing and speaking well enough by now to be able to register us, which is normally her job.  We were escorted to a water/electric pull-through site in the center of the park with less than ideal access but I was able to get in and park the bus.  We leveled as best we could, shut off the engine, batteries, and air and then plugged in the shorepower and turned it on.

Linda made a really good salad for dinner and we each had a piece of leftover pizza, slightly warmed.  Yum.  After dinner I made calls to Joe Cannarozzi, Ed Roelle, and Butch Williams and sent a text to Pat and Vickie Lintner.  Joe was working on a coach in Williamston, Michigan and was looking for a local facility that could service the over-the-road air-conditioning system.  Ed has been around converted buses in Michigan for a long time so I contacted him to see if he had any suggestions for Joe.  We went for a long walk around the campground during which I had a long chat with my sister.  When we got back to our coach I exchanged text messages with Smitty back at Willison Crossings RV Resort.

Our TV options were limited but we were able to get PBS, so we watched whatever was on.  We planned to pullout out of our site at 7 AM, which meant we had to be up around 6:15.  Not that we have that much to do, but we do not like to rush through our morning routine.  We were in bed with the lights out by 11 PM.

2016/04/14 (R) A Relatively Smooth Run

There was a possibility of rain last night so we closed all of the roof vents and narrowed the window openings before we went to bed.  I set the alarm on my phone last night for 6:15 AM this morning, but I was aware of the rain, and woke up around 4 AM when I heard one of the cats making a strange noise.  I wanted to turn on the electric engine block heater anyway so I got up and did that, checked on the cats (they were fine), and went back to bed.  I tried to go back to sleep without complete success.

We finally got up to stay at 6:30 AM and got dressed.  I had an e-mail from Gary at BCM that needed a reply and cc:d Dave Aungier.  I also texted Dave as he was who Gary needed to contact.  I shut down all of the technology and packed up my computer while Linda cleaned off counters and secured windows.  The car was already connected for towing so we just had to go through the towing procedure and double check it.  I disconnected and stowed the shorepower cable, connected the chassis batteries, and opened the air valves in the engine bay.  I started the engine and we did the light check while the chassis aired up.  Since it was 7 AM we tried to avoid idling any longer than necessary before pulling out.

We were in an angled water/electric site in the middle of the campground with fairly tight ingress and egress.  I raised the tag axle so shorten the turning radius and pulled out while Linda kept an eye on the driver side front corner.  I had to get the driver side nose of our coach fairly close the passenger side rear corner of the 5th wheel trailer directly in front of our site in order to get our passenger side rear end and toad to clear a tree on our site and a post near the road on the next site to our passenger side.  I also had to avoid the rear end of the next 5th wheel trailer and the picnic table in-between them.  Fun.

Without being over-confident, I think I have gotten a lot better at maneuvering the bus in tight situations.  That skill has come with some good teaching, some practice, and at the expense of two mistakes that caused some damage, but it certainly paid off this morning.  Once I was cleanly out of our site and into the road I stopped and put the tag axle down.  Linda got on board and we rolled slowly out of the center of the campground and headed for the exit.  We stopped before exiting so Linda could find Juniper.  We knew she was onboard, but we wanted visual confirmation before pulling out.  Linda found her under one of the living room captain’s chairs, and we were on our way.

We recharged the Rand-McNally GPS last night using a 12 V car outlet splitter with USB ports and a compatible USB cable that I borrowed from the Sony a99v DSLT camera.  Linda turned it on and entered the address of today’s destination to verify that the unit was working.  It was, so I set it up on the dashboard by the windshield center pillar so it was ready to go this morning.

Our route took us north on the final 70 miles of I-75 in Georgia to Chattanooga, Tennessee where we headed northwest on I-24.  I-24 was mostly in Tennessee, but dipped back into Georgia briefly as it swung around the southern side of a mountain.  Unless you head far to the west on I-10 before turning north, there isn’t a practical way to get back to Michigan from Florida without crossing mountains.

As you head north from Florida on I-75 the ground rises steadily.  As you approach Atlanta it starts to get hilly, and that continues north of town all the way to Tennessee.  As soon as you head west on I-24 you are perpendicular to mountain ridges running SW to NE.  The highway winds around these ranges, sticking to valleys as much as possible, but inevitably there comes a point where it simply has to go over the top.  And so it did.  I think the grade was at least five miles long, perhaps seven, with lots of turns but nothing I would call a switchback.  The road surface was excellent with wide lanes and truck lanes.  The grade was just steep enough that I had to climb it in 4th gear doing around 50 MPH at 2000 RPM with 14 to 15 PSI of turbo boost.  With cool outside air the engine coolant temperature never rose above 195 degrees F, which is its normal operating temperature (on the gauge) and I was very pleased with the way the bus ran.  Replacing the turbo boost sensor tube last year was no doubt partly responsible for this performance.

The temperature was in the low 50’s when we left the Cartersville Castle-White KOA around 7:15 AM and we ran through cool temperatures under overcast skies, with intermittent drizzle and fog, all the way over the mountains in southwest Tennessee.  Once we were on the northwest side of the mountains the cloud cover started to break up and reveal patches of blue sky.  Somewhere southeast of Nashville we encountered our last raindrops and by the time we merged onto northbound I-65 we had clear, blue skies.  Traveling “north” from late morning to early afternoon we had the sun at our backs, making for a comfortable cockpit without using the air-conditioning.

I was concerned about the issue we had yesterday with the Battery Balance (BAL) telltale caution light and the Hi/Low Battery (Voltage) telltale warning light and presumed it would reoccur today.  In order to reduce the chance of that happening again today I tried to minimize the power draw from the +12 VDC center tap of the chassis batteries and perhaps cause an imbalance between the upper and lower halves of the battery bank.   To that end I did not use the cockpit HVAC fan and kept the headlights off as much as possible.

We had a pretty smooth run all the way to and through Nashville.  Pat and Vickie had alerted us to “construction on I-65” but were not more specific.  North of Nashville we encountered a major construction project that lasted for at least 20 miles.  Traffic flow, however, was very smooth if a bit slower than normal posted speeds.  As we approached Louisville we saw signs announcing major construction ahead and advising I-283W as an alternate route.  We were less than 15 miles from our destination and needed to take the second exit just after the bridge so we rejected the alternate route suggestion and stayed on I-65.  The construction was, indeed, major—the reconstruction of a bridge over the Ohio River—but we made it through without having to stop.  The campground website had very specific and detailed directions on how to exit I-65 and we followed them instead of the GPS.  We were momentarily confused after exiting, never a good thing when driving a bus in an urban area, but we were in the right place and made the last couple of turns to get to the Clarksville KOA campground without difficulty.

Linda checked in at the office and the woman at the desk lead us to a pull-through site that was very easy to get into but might be challenging to exit in the morning.  We were sitting level without having to adjust anything so I shut off the engine and we went through our usual arrival routines.  Linda then walked over to the office and finished registering us.

We walked the park, which was not large, and scoped out our departure route and any possible problems.  The sites here are closely spaced, the roads are a little narrow, and some campers are parked with their vehicles sticking part way out into the road.  Some of the people camped here appeared to be younger men who were itinerant workers.  As such, we suspected they might be gone in their cars before we pulled out in the morning.  If so, we will probably get out OK without having to unhook the car, but I doubt that we will ever return here.  While the location is convenient to I-65 and Louisville, the park itself is not worth the $50 a night they charge.  If not for the location, it wouldn’t be worth half of that.

We did not plan to unhook the car to explore the area and there did not appear to be anywhere to walk although Vickie had texted us that we were only a half mile from the river and there was, in fact, a nice walk down to there.  Even so, we were tired and perfectly content to retire to our coach, have dinner, and watch our favorite Thursday evening CBS comedy shows.  We went to bed at 11 PM as we planned to be on the road at 7 AM so we could be at Butch and Fonda’s home in Twelve Mile, Indiana before noon.

2016/04/15 (F) Back In Twelve Mile Again

I set the alarm on my smartphone last night for 6:30 AM this morning.  Like last night, I woke up around 4 AM, turned on the engine block heater (electrical), and tried to go back to sleep.  I was awake again before 6:30 and the alarm was just my signal to actually get out of bed and get dressed.  Linda woke up with the alarm and was also up and dressed fairly quickly.

As usual for a travel day, we did not make coffee or have breakfast and instead set about preparing the coach for travel.  I had turned off my computer last night so all I had to do was pack it up.   We also left the car and bus connected together, so all we had do was check the connections and go through the towing procedure.  I turned the block heater and Aqua-Hot electric heating element off, disconnected the shorepower cord and stowed it, opened the auxiliary air supply valves, and started the main engine.  We did a light check while the chassis aired up and then Linda climbed aboard.

I was concerned about getting our rig out of the small, tight site and through the narrow interior gravel roads of the campground, but our neighbor’s to the left moved their truck before they went to bed last night and the guy directly in front of us on the other side of the street left in his car just before 7 AM, presumably to go to work.  That meant I had plenty of space to pull forward and to turn to the left, which is the direction the site was angled.  By 7:25 AM we were exiting the park and on our way to Twelve Mile, Indiana.

Although we had less than 200 miles to travel today, I-65 continued to be one long construction zone with lots of very rough surfaces which made for more difficult and tiring driving.  In-between Clarksville and Twelve Mile was Indianapolis, so that meant major urban traffic.  “Indy” is a major shipping hub with a good, but extensive highway system.  I-465 circles the metro area while I-65, I-69, I-70, and I-74 all tie into it, along with several U.S. highways.  The speed limit is 55 MPH and most drivers seemed to obey it, which made for easier urban driving, but there was still a LOT of traffic.

As we got on the north side of town headed west we were looking to exit onto US-31 north.  The GPS told me to exit at Keystone Avenue and turn right onto the relatively new Keystone Parkway, which bypasses the initial stretch of US-31 before joining it some miles farther north.  Fortunately I spotted a sign before exiting the highway that said vehicles over 19,000 pounds GVW were not allowed on the Parkway.  Also fortunate was that I knew the exit for US-31 was only a couple of more miles ahead and was a perfectly acceptable place for us to get off of I-465.  I had not been this way in a while and discovered, to our pleasant surprise, that it is a completely new, limited-access highway heading northbound.  Sweet.

We handled the situation smoothly and without too much consternation, but it was concerning that our GPS tried to direct us onto a road for which we were too heavy by more than double.  That had us wondering if the RV characteristics parameters were not set correctly, and perhaps got reset when I updated the unit while we were at Florida Grande Motor Coach Resort, but now was not the time to check all of that.  This is a relatively recently rebuilt roadway, and it was been my experience with both GPS units that the map updates do not include these newer roads.

Another possibility was that the Indiana Highway Department has not updated the state road database as that is where Rand-McNally (and other mapping companies) get the information for their road maps.  I encountered this a while back when traveling US-24 from Peru, Indiana to Defiance, Ohio.  Even though my GPS database was up to date, it had no knowledge of the new construction between Ft. Wayne, Indiana and Defiance.  The same us still true of the new stretch of US-31 running south from US-20 for many miles even though it has been open for quite a while.  The State highway departments are responsible for updating the database that the GPS/mapping companies use.  If they do not update the database there isn’t much the GPS/mapping companies can do.

Indiana has made major improvements to US-31 over the last 3 to 4 years, building whole new limited access sections.  Besides the section coming south from US-20 and the section going north out of Indianapolis, there is one that now bypasses Kokomo.  The older sections are four lane divided but have grade crossings and occasional traffic signals.  They are posted at 60 MPH and traffic is usually light and moves along well.

All-in-all we had an easy final leg from Indy up to State Road 16 and west into Twelve Mile.  At 11 AM, just 3-1/2 hours after we pulled out of the Clarksville KOA we were back in Twelve Mile again.  We pulled into the gravel driveway for the grain elevator, which is not in use this time of year, to unhook the car.  The driveway is exactly opposite where I park the bus when it is here and positions me to basically back across SR-16 into our spot next to Butch and Fonda’s bus.  Linda spotted for me as I backed across SR-16 and into our spot.  I leveled the coach, shut off the engine, and took care of the exterior arrival tasks while Linda took care of the interior ones.

Butch and Fonda did not come out of the house and we were not sure they were home.  We usually have a very poor Verizon signal when the bus is parked in this spot, and today was no exception, but I was able to get our Verizon Mi-Fi online.  About that time Butch and Fonda came out to check on us and we visited for a while.  We had not knocked on the door because we knew there was a possibility they might not be home when we arrived.

Butch needed to be at a local county fairgrounds at 5 PM to help set up a large room for a hamfest tomorrow.  Fonda was reviewing for the General Class license exam, so Linda studied her Amateur Extra Class flash cards with Fonda while Butch and I went to the do the set up.  The hamfest was an annual joint event put on by four county amateur radio clubs.  After the tables were all set I helped Butch carry in all of the stuff from his truck and arrange it on three adjacent tables.  When we were done, and there was nothing else to do, we returned to Twelve Mile.

It was 6:30 PM by the time we got back and we decided to go out for dinner even though the options for us are very limited.  We drove to Rochester hoping to eat at a Mexican restaurant but it was closed (permanently).  We ended up at Tweedle Dee’s instead, mostly because they have a salad bar.  We were the last diners to leave and only then because they needed to run the vacuum cleaner which cut off any chance of Linda hearing any further conversation.  We stopped at Butch and Fonda’s new (to them) house on IN-25 in Metea but Butch did not have the key with him so we did not get to go inside.

By the time we got back to Twelve Mile we were all tired.  Butch and Fonda had to be up very early to go to the hamfest so they signed their tax returns, got them ready to mail, and brought them to our bus for Linda to mail in the morning.  I planned to go to the hamfest too, but not first thing in the morning.  I also wanted to take our car so I could come back to Twelve Mile before the hamfest ended at 1 PM.

Our series of equipment failures seems to be continuing as I was unable to get the Amped|Wireless SR20000G router/network-extender to recognize any hard wired devices.  I tried plugging in both my computer and our NAS to all five of the ports but none of them responded to either device.  It’s unlikely that the wired networking had failed on both the computer and the NAS so the failure of the SR20000G is the more likely cause.  The SR20000G’s wireless networks are still working but the loss of the wired ports means I cannot access the NAS.  Fortunately we will be home in a few days and I can try to sort this out in the comfort of my office.

Being tired, and with no TV reception, we were in bed by 10:30 PM and I was asleep by 11 with no alarm set for the morning.

 

2015/08/19 (W) If It’s Wednesday This Must Be Indiana

 

As we did last Wednesday we were up earlier than usual to drive to Indiana.  We wanted to be at Bontrager’s Surplus when they opened at 9 AM to pick up some battery terminal covers for Butch, and possibly ourselves, so we pulled out of our driveway at 6:16 AM.

We took our usual route west on M-59 to I-96W to Lansing Road south.  Rather than get on I-69S we stayed on Lansing Road all the way to Charlotte where we stopped at the Biggby’s Coffee to use the restroom and get coffee and bagels.  From there we then took I-69S to Coldwater and headed west on US-12 since Bontrager’s Surplus is located on US-12 in White Pigeon, Michigan.

We arrived at Bontrager’s Surplus just after 9 AM.  We looked around briefly but did not spot the battery terminal covers so we asked one of the employees where they might be and he took us directly to them.  We bought 36 (18 red and 18 black), 10 of each for Butch and 8 of each for us.  Bontrager’s is probably the best stocked of the surplus and salvage stores in this area and I could have spent hours here, but we had other places to be and a long day ahead of us.

Our shopping done we continued on to Coach Supply Direct in Edwardsburg, Michigan where we found Josh Leach hard at work on some interior remodeling of a Fleetwood Revolution.  He removed the Notion Linen sample from his Lambright Comfort Chairs book and we chatted for a while.

I reflected on fact that one of the nicest Class A motorhomes we ever saw was a Fleetwood Revolution.  The interior was a (faux) cherry wood with satin finish nickel hardware.  It had modern, clean cabinetry and light grey wall treatments and a light tile floor with nickel colored inserts, as best I can recall.  We eventually toured the American Coach factory in Decatur, Indiana where the Revolution was made and after seeing some of the construction methods we were less enamored with it.  Like all of the American Coach products it was out of our price range as a new unit but it was very much to our taste.

Before continuing our Journey Linda pulled up Jarel’s address in our GPS.  I then texted Jarel to give him a revised, and more accurate ETA.  We headed southwest out of Edwardsburg on M-62 which becomes IN-23 through Granger.  We turned onto IN-331 which bypasses most of Mishawaka east of town and delivered us to US-20 where we headed west.  We stopped at the Meijer’s, which has a filling station, fueled the car, and switched drivers.  We exited US-20 just south of South Bend, Indiana and headed south on US-31.  We exited US-31 at Rochester and took IN-25 south to Logansport.  I texted Jarel an updated ETA enroute.

We arrived at Jarel Beatty Cabinetry at 11:45 AM and pulled around back.  I texted Jarel to let him know we were there and he came out of the shop to meet us.  We chatted for a while, loaded up the pantry, the slides, the three pieces for the built-in sofa that we forgot last week, a piece of walnut trim for the pantry face, and a leftover  piece of 1/4″ Baltic birch plywood.  Linda wrote a check for the balance we owed.  The only thing left for Jarel to build is the HVAC/wiring chase cover but he cannot do that until I give him the length, which I cannot do him until the desk is installed in the bus.

We left the cabinet shop at 1 PM and stopped at the Martin’s supermarket in Logansport for lunch.  This particular Martin’s did not have a salad bar but they did have pre-made salads.  We each had one along with a bread roll.  I called Butch to let them know we were on our way, and headed for Twelve Mile, Indiana.

I gave Butch the battery terminal covers.  He and I figured their cost ($1.25 each) covered the cost of the 12 fiberglass pole mast sections ($2.00 each) we took last week and called it even.

I brought the small window frame stop block from our bus to see if Butch could make one.  He had some aluminum bar stock that looked like it would work.  We decided to make it longer than the original to accommodate three machine screws and cut it to size using a band saw.  Butch then marked three points to drill holes using the old block as a template.  Two holes were drilled through and one end hike was blind.  The blind hole will fit over the shaft of the old screw that would not come out in case any of it is still protruding above the surface.  The middle hole will line up with other existing hole and I will have to drill and tap a hole in the frame to match the third hole.  But first I need to get some brown spray paint, put some sacrificial screws in the holes, and paint the piece.

While we were working on the stop block I noticed that Butch had a torque multiplier sitting out.  He commented that it was available to a good home for a good price; hint, hint.  These torque multipliers are used to break the lug nuts loose on bus and truck wheels and I have had one on my mental wish list since I first became aware of them five years ago.  I had not pursued getting one as they tend to be expensive even used on Ebay.  Butch wanted $75 for it so I wrote a check and put it in the car.  It has three different lug nut sockets so I hope one of them first the ones on our bus.  I also hoped they would fit the very large torque wrench I bought from Butch last fall but they are 1″ square drive sockets and the torque wrench has a 3/4″ square stud.  I’m not sure I have a correct socket for the torque wrench so that’s another thing I still need to get.

Butch and Fonda bought a compact stacked clothes washer/dryer for their bus and asked if we would help them get it into their rig.  Of course we said yes.  We got it on a dolly and wheeled it out to the entrance door and then pondered the situation.  We have some recent experience getting things out of and into a bus entrance door and this did not look promising.  Butch handed me a tape measure and I determined that the maximum width that would fit through the step well was 23.5 inches due to the door hinges.  The washer/dryer is 24″ wide and 28″ deep with a recessed back on the washer (lower unit).  It is also tall, being a stacked unit, and we all agreed that the only way it was going in was on its back, through a window, using a forklift.  It was Deja vu all over again; been there, done that, didn’t even get a T-shirt.  That approach required more preparation than Butch cared to tackle today, and more time than we had to spare, so we moved the unit back under the overhang and left it covered with a blanket.

We all went back in the house and visited for a while longer.  Butch had found his 4″ pneumatic body sander and loaned it to me along with three boxes of AA50 sanding discs.  While not quite as aggressive as the #36 ceramic grit belts I have been using on the 4″ portable belt sander, this tool will allow me to get under the cabinet toe kicks where the belt sander won’t reach.

As much as we would have liked to stay and go out to dinner again, we did not want to be getting home at midnight.  We wished them a safe journey, again, but this time it really is unlikely that we will see them again before they leave for Arizona.  We left for home at 4:45 PM with Linda at the wheel.  From SR-16W (CR-700N) we took CR-700 (Meridian) north to its northernmost point and headed west into Fulton on W750S where we picked up IN-25 and headed north.  At Rochester we left IN-25 and took US-31N to US-20W.  We exited US-20 at SR-19 and drove north through Elkhart, finally arriving at the Martin’s supermarket at CR-4 around 6:15 PM.  This Martin’s has an excellent salad bar and a nice dining area with an upstairs, which is where we chose to sit and eat our dinner.

Linda continued to drive after dinner.  There is an entrance to the Indiana Toll Road (I-80/90) on SR-19 just south of CR-4 so we got on going east.  The toll road is a few extra miles compared to US-12 through Michigan, but it is posted 70 MPH (max) with no stops, compared to 55 MPH with six towns that have reduced speed limits and stops.

We exited the toll road, paid our $2.90 toll, and headed north on I-69.  A few miles later we were back in Michigan.  We left the Interstate at M-60 (exit 25) to refuel at the Shell station, use the restrooms, and switch drivers.  It was about 8 PM and still light, but it was cloudy to the west and the light was fading.  I find night driving easier than Linda does and I had been able rest while she drove so I was good to go.

I followed our usual route, leaving I-69N and using the Lansing Road cutoff to get to I-96E.  We passed mile marker 100 on the south side of Lansing, which meant we had 33 miles to the M-59 exit.  From there it was 11 miles to Hacker Road and then the final 2.5 miles to our house.

We arrived home at 10 PM, five hours and 15 minutes after we left Twelve Mile and just over 16 hours from when we left home this morning.  The trip odometer indicated 534.8 miles traveled today.  We unloaded the camera, phones, wallets, etc. from the car but decided to wait until tomorrow to unload the cabinetry, tools, and parts.  We headed off to bed and watched part 3 of a PBS program The Mystery of Matter:  The Search for the Elements.  Interesting stuff.  We both find programs that inform and educate to be entertaining.

 

2015/08/12 (W) Back to Indiana (Again)

Today was early arrival day for the annual Back-to-the-Bricks converted bus rally in Clio, Michigan.  This joint rally of the Converted Coach Owners (CCO) and the FMCA Great Lakes Converted Coaches (GLCC) chapter has become an annual event that typically draws 20 to 30 rigs.  Most of them are converted highway buses and many of those were converted or re-modeled by the owners.  Many of them are works in progress but such is the nature of the bus conversion hobby and the true bus nut.  But that is not where we were headed today.  Our bus is unusable at the moment as the toilet is disconnected, the bed platform has been removed, and all of the cabinet drawers have been taken out.  But the main reason was that we had multiple commitments in Indiana today.

Our first appointment was with Josh Leach of Coach Supply Direct.  Although CSD is located in Edwardsburg, Michigan we had arranged to meet him in the parking lot of the Martin’s Supermarket at SR-19 (IN) and CR-4 on the north side of Elkhart, Indiana at 9:30 AM to take delivery of 15 yards of upholstery fabric.  We picked that location, rather than his shop in Edwardsburg, for several reasons.  He had to be at the Forest River Owners Group (FROG) rally at the Elkhart County 4-H Fairgrounds at 10 AM so that location got him half way to his destination at a good time of day.  For us, Elkhart is a 3-1/2 hour drive.  That meant we had to be up at 5:00 AM and on the road not later than 5:45 AM to be there on time, allowing for coffee, fuel, and bathroom stops.  Had we met him at his shop we would have had to be there by 9 AM requiring us to get up even earlier.  You have to draw a line somewhere.

I took the wheel for the start of the trip.  It was still dark but the faint glow of the impending sunrise was visible as we pulled out onto Hacker Road facing a rising crescent moon.  At M-59 we headed west to I-96.  I reset one of the trip odometers before we left and verified that it was 13 miles from our driveway to the end of the entrance ramp from M-59 onto I-96W.  We skirted the southern edge of Lansing on I-96 and took Lansing Road to I-69 south.

Nineteen miles south of Lansing, and about an hour into our trip, we stopped at the Biggby’s Coffee in Charlotte for coffee and bagels.  Biggby’s is not my favorite coffee but this particular store is in just the right location.  Linda checked the M-DOT website and it appeared that the bridge work on M-60 in Mendon was completed, so we exited I-69S and headed west on M-60.  Unfortunately the bridge was still closed so we had to follow the detour to the south toward Sturgis.  Unlike our previous trip in early July, when we continued on to Sturgis, we followed the complete detour through Nottawa and Centreville and back to M-60 in Three Rivers.  We had never driven through Nottawa or Centreville before so that provided some new scenery for the trip.

As we have done many times before we continued our trip on M-60 as far as Jones where we stopped at the Shell station for fuel.  We then took M-40 south to US-12.  This seven mile stretch of M-40 traverses steeply rolling hills and is both beautiful and fun to drive.  We took US-12, running west just north of the Michigan-Indiana border, and eventually exited onto Old 205 (M-205?) which turns 90 degrees to the left a mile later and drops straight south into Indiana where it becomes SR-19.  A few miles later we arrived at the Martin’s Supermarket at CR-4 just after 9 AM.

Josh was not there yet so we went inside to use the restrooms and get some coffee.  This particular Martin’s has a nice salad bar with a beverage station, a Starbucks Coffee outlet, and a seating area with Wi-Fi.  Josh showed up right on time and parked next to us.  I met him outside and we transferred the roll of upholstery fabric from his car to ours and then went inside to visit for a few minutes before he had to leave for Goshen.

When we left Linda took over the driving.  Our next planned stop was A1-Upholstery in Elkhart to order the cushions for our built-in sofa.  Continuing south on SR-19 we stopped at Factory RV Surplus to look for battery cable end covers but the ones they had were too expensive.  I think they now sell more retail-packaged merchandise than they do true surplus material, and even less salvaged parts.

Lou (mom) and Terry (daughter) own and operate A-1 Upholstery and were recommended to us by Josh.  We discussed the project with Terry, who I had previously spoken to on the phone.  We reviewed my dimensioned scale drawings, which were on one sheet of 11″x17″ 1/4″ grid-square paper, and agreed on how the cushions would be made.  Terry thought she would have them done by the end of the month but noted on the order form that we needed them by September 14th.  We noticed that she had a lot of sample books from which we could have selected a fabric but we like the Lambright Notion Linen, and Terry thought it was a very good fabric that should look good and wear well in our application.  We left the fabric and drawing with her and wrote a check for the deposit.

All of our stops were important today, but our primary reason for the trip was to pick up the pieces of the custom desk and built-in sofa for our bus from Jarel Beatty Cabinetry in Logansport, Indiana.  We continued our trip south on SR-19 to US-20, took that west to US-31, and went south, exiting at Rochester onto IN-25 for the final 22 miles to Logansport.  This is a route I have driven many times but Linda had the wheel this time so I provided some occasional guidance.  I called Jarel to let him know we were making better time than we had anticipated and would be there between noon and 12:25 PM.  I then called Butch to give him a status update.

This was the first time Linda and Jarel had met and so it was also the first time Linda had met Mya, Jarel and Georgette’s sweet little dog.  Mya came up to me, sat, stared up at me like we were long lost friends, and waited patiently for me to give her the attention she was seeking.  I was happy to oblige.

Jarel Beatty Cabinetry, Logansport, IN

Jarel Beatty Cabinetry, Logansport, IN.  Panorama taken from the entrance door.

Jarel Beatty Cabinetry, Logansport, IN.

Jarel Beatty Cabinetry, Logansport, IN.  Panorama from the center of the shop.  Entrance door is far left.

As I have previously described in this blog, the desk consists of nine pieces (if you count the four drawers as separate parts):  two pedestals with separate bases, a cover that goes between them, and four drawers.  The left pedestal has a fold up work surface with two support wings, and a fold down fake drawer front, so technically those are four more pieces, but they are attached to the pedestal with hinges so I am not counting them as separate parts.  The bottoms of each pedestal have been cut out to provide access to the fan-coil heat exchangers that will be installed in the bases, so those are really two separate pieces now, put I am not counting them as such.  I am also ignoring screws, drawer slides, blocking, and other assembly items in my parts count as they are all “installed components.”  With the drawers installed we only had five major pieces to load plus the two access plates.  Jarel also had the pieces ready for the built-in sofa so we loaded those as well.  I took pictures of his shop and the pull-out pantry, which was mostly assembled but not quite finished.

The installed desk will have more pieces than just described but these are the pieces that Jarel made.  The finished desk will have five grills that we have to cut and install, at least four drawer pulls that we have to install, a plywood top that will span the two pedestals and leg space, and a Sandstone Corian countertop that will go on top of the plywood.  While not actually part of the desk there will also be a large cover for the passenger-side living room HVAC duct and wiring chase and a small hose cover at the desk end both of which align with the left end of the desk and will look like they are part of it.  Jarel will make the chase cover later after the desk is installed and we can get a final, accurate measurement for its length.

As long as we were in the neighborhood we naturally stopped to visit with our friends, Butch and Fonda, in Twelve Mile, Indiana.  While we were at their house we loaded a dozen 4-foot army surplus fiberglass mast sections in the car.  Butch had bought these at a swap for me some time ago.  We will use them for ham radio antenna projects.  Butch gave me his old, non-functioning, Vanner battery equalizer to see if I can figure out how it does what it does.  He also lent me his air-powered brad nailer which can also drive 1/4″ crown staples and gave me a box of 5,000 staples to go with it.  Fonda found a scrap piece of resilient underlayment designed for free-floating wood floors.  Butch though it might work well under the 1/4″ plywood underlayment to fill in the gaps and irregularities so we took it with us.

When we were done loading stuff into our car we went to see their new property on SR-25.  They have already had a new roof put on the barn and new doors put in the house.  They have bought themselves a BIG project, but it will be a much more appropriate and manageable place for them going forward than the building complex in Twelve Mile that has housed their business operations for the last 20 years.  It’s an old GM dealership from the 1940s and they have approximately 11,000 feet under roof including a 2-bay service garage with a functioning in-ground lift.

We drove to Rochester and had dinner at Pizza Hut.  Linda and I split a medium specialty veggie pizza and had the salad bar with it.  We might have had a few more restaurant choices in Logansport, but Rochester was 22 miles closer to home.  With the 19 hours we were gone today, and over 525 miles we had to travel, 22 miles and 30 minutes was significant for us.

We got back on the road at 6:30 PM with Linda at the wheel and headed back up US-31N to US-20 and headed east.  We decided to stay on US-20 all the way to I-69, stopping in Lagrange to use the restroom at the Marathon complex.  We stopped again at the Shell station on M-60 in Michigan for fuel.  It was getting dark and I had been able to rest while Linda drove, so I took over the driving duties.  From this point on we were just reversing our route from this morning.  We got home at 10:30 PM, unloaded everything from the car, and then went straight to bed.

 

2015/04/21-25 (T-S) IN, MI, Home

2015/04/21 (T) Back to Twelve Mile, IN

The outside air temperature dropped into the 30’s (F) last night and the air temperature in the coach fell to 60, so when I got up this morning I turned on the Aqua-Hot diesel-fired hydronic heating system to take the chill off.  We eventually got up, got dressed, and walked across to Small Town Brew to get a couple of cups of coffee and chat with owner Lisa Paul and her friend/neighbor, Ashley, who helps her run the coffee shop.  Both of them remembered both of us, which was nice.

It’s interesting sitting in a small town coffee shop, where everyone is a friend or relative, and just listening to the conversation.  We are outsiders her, of course, strangers to most of the folks who drop in, but everyone is nice to us.  Some are curious about who we are, and where we are from, but rarely ask why we are there, in this little coffee shop in this little town, surrounded by corn fields.  Of course, we usually mention that we are friends of Butch and Fonda, so that probably answers whatever questions they may have had.

We eventually returned to our coach and had breakfast.  We tried connecting our WiFiRanger to Butch and Fonda’s Wi-Fi router yesterday and it was able to connect and obtain an IP address but the data transfer rate was so slow that web pages would not load and e-mail would not download before timing out.  I turned our Verizon Mi-Fi on and we had a very weak but usable signal, so I connected the WFR to the Mi-Fi and we were able to do the few things we needed to do online.  We then went in the house to let Butch and Fonda know we were awake and see what they were up to.

Butch’s brother, John, and his nephew, Brock, showed up and helped Butch with the driver side front wheel assembly on Butch and Fonda’s MC-9 bus.  The tire/wheel was off when we arrived yesterday and I learned that Butch is replacing the hub bearings and seals, installing an automatic slack adjuster for the brake, and replacing the brake pads.  It looked like quite a job with some large, heavy parts, so I did my part by staying out of the way.  I also took a few pictures at Butch’s suggestion.  He does not want to write articles for Bus Conversion Magazine, but he has been interested in having me write articles about projects on his bus.

Linda spent some time working with Fonda’s new sewing machine that she got while they were in Quartzsite, Arizona.  It is a little smaller than a regular sewing machine, only weighs 13 pounds, and only cost about $130.  Linda gave her sewing machine to her sister many years ago but now that she is retired she is thinking that it might be nice to have one for mending tasks or projects, such as new privacy curtains for the bus.

Butch got a catalog recently from Crimp Supply in Royal Oak, Michigan, which is not at far from our house.  I glanced through it last night and it contains a lot of specialized parts that would be useful to a ham radio hobbyist or someone converting a bus into a motorhome.  I called and requested a catalog and had a nice chat with Debbie.  She was willing to provide me with additional catalogs that I can give to members of GLCC and CCO at the Back-to-the-Bricks and/or Surplus & Salvage per allies in August and September respectively.  She was also willing to show up in person and give a brief presentation on her company and hand out the catalogs.  Cool.

Brock had to leave after which Butch and John decided to go to the shooting range along with a third guy whose name I did not get.  I went along to see the range and watch what they were doing.  Butch had home-brewed some shotgun shells for his Ruger revolver and wanted to test them.  They caused the revolving chamber to jam so they will require some additional work.  John had a new semi-automatic pistol and wanted to see how it handled.  He also had ammunition he had loaded with bullets he had cast and wanted to test fire them.

I was offered the opportunity to shoot but declined.  I have never handled a pistol and it would have been a waste of good ammunition.  I did take a class in rifle marksmanship while I was at the University of Missouri – Columbia many years ago.  I was in the Air Force R.O.T.C. Program at the time and thought I should know something about how to handle a firearm.  Learning to handle a pistol correctly would have been more relevant, but I do not recall a course being offered for that.  I bought a Ruger 10-22 rifle at that time, and I still have it.  It’s a .22 caliber semi-automatic rifle designed to look like an M-1 carbine and features a 10-round rotary clip that is flush to the bottom of the stock when inserted.  I was only interested in shooting at paper targets so I added a scope to it.  It is safely tucked away with a trigger lock on it, but I have not fired it in many, many years.  I should probably bring it to Twelve Mile the next time we come down, let Butch inspect and clean it properly, and take it to the range just for grins and giggles.

John and the other guy went back to Logansport from the range.  When Butch and I got back to the house he continued working on the driver side front wheel of their bus.  I helped a little, but mostly by taking photographs for a possible future article.  After putting tools and parts away we sat and relaxed for a while and then all of us went to Logansport for dinner at Pizza Hut.  It was 8:45 PM by the time we got back so everyone said “good night” and turned in for the evening.

2015/04/22 (W) Chillin’ in Twelve Mile

Yesterday looked and felt more like winter than spring with gray, cloudy skies and blustery, cold winds.  The temperature overnight dropped into the mid-30s but we were toasty warm under blankets with our electric heating pad turned on.  I got up at 7:30 AM and turned on the thermostats.  The temperature in the kitchen was reading 63 degrees F but the temperature by the dashboard was only 53.  The Aqua-Hot has performed very well since I rebuilt the blower bearings and quickly brought the temperature in the coach up to 70 degrees F.

We put on our sweats and walked over to Small Town Brew for coffee and conversation with owner Lisa Paul and whomever else might be there.  Three local guys were enjoying their morning brew when we arrived.  They eventually left and were replaced by others.  Most of the patrons seemed to be retired or semi-retired farmers.  One fellow, Lee, chatted with us at length about a canvas covered hoop barn he put up.  It was constructed using laminated wood hoops rather than steel, was 30′ wide by 70′ long and cost about $4,000 15 years ago, although I was not clear whether that included the 4-foot high poured concrete walls.  He already owned concrete forms and the heavy equipment that one finds on farms, so he was able to do a lot of the work himself without renting equipment or hiring contractors.  Still, it has to be the lowest cost way to create a structure for getting our bus out of the weather and out of sight.  It is unknown, however, whether the Township and County would let us to put it up.

Butch left at 8:30 AM for medical appointments in Logansport and Fonda came over at 10:45 AM to gather up Linda for a girl’s day out.  Linda wanted to go to McClure’s Apple Orchard on US-31 between IN-16 and US-24.  Although it is very close to Twelve Mile Fonda had never been there.  They were then headed to Peru.  Although it is the same distance from Twelve Mile as Logansport and Rochester it is the city that Butch and Fonda visit the least.  Peru’s claim to fame is that it was the birthplace of Cole Porter and Emmet Kelly and was the winter home of several circuses many, many years ago.  I believe there is a circus museum there that Nick Russell wrote about in the Gypsy Journal.

With no bus project or social interactions I settled in to work on my blog and await everyone’s return.  It started out sunny this morning but by 11 AM was thickly clouded over and looking wintery with blustery winds.  The only bus project I had in mind to do today was to pull out the chassis batter tray, check the circuit breakers, disconnect the batteries, swap the upper 12 V pair with the lower 12 V pair and reconnect them.  It was not something I wanted to do alone and I did not have to do it today, especially under cool, windy, overcast conditions, so I ended up not doing it.

Linda and Fonda eventually returned, having first gone to the Walmart in Logansport.  Linda picked up some hummus and Snyder’s sourdough pretzels so we snacked on those for lunch.  Linda then hung out with Fonda while I continued to work in blog posts.  Butch finally returned from his medical appointments and busied himself with something.  Whatever it was, he was not outside working on their bus and neither was I.  I managed to get the post for April 1 – 3, 2015 uploaded to our blog.

Linda and Fonda developed a plan for dinner.  Fonda made a nice salad and baked a loaf of par-baked bread that we got from Marilyn.  Linda made black beans and rice and prepared a mix of fresh blueberries and strawberries for dessert.  Linda and I each had a glass of Franzia Red Sangria.  After taking all of dirty serving containers back to our coach we returned to the house to visit a bit longer and finally returned to our coach just after 9 PM.  That left me enough time to pull together the posts for April 4 – 6 and upload it before turning in for the night.

2015/04/23 (R) Return to Michigan

I was awake at 6:30 AM and finally got up at 7 and put on my sweats.  The Aqua-Hot was already on so I turned up the thermostats and turned on the engine pre-heat loop.  I also turned on the Broan cube heater and pointed it into the cockpit as the temperature on the dashboard was only 50 degrees F.  I walked over to Small Town Brew, got a cup of coffee, and said “so long for now” to owner Lisa Paul.  Linda was still asleep when I got back so I fixed a couple slices of toast for my breakfast, turned on our Verizon Mi-Fi, and settled in to take care of a few e-mails.  Linda finally got up and, as I suspected, had not slept well last night.  She had some toast and orange juice but had no interest in coffee, a strong indicator of just how tired she was and not feeling completely well.

When she was done with the toaster I turned the cube heater off and turned the electric block heater on.  The overnight low temperature was forecast to drop into the upper 20’s and starting the big Detroit Diesel at that temperature is hard on the engine so I wanted it nice and warm before I cranked it over.

Butch had an appointment with an ophthalmologist in Indianapolis around noon and had some other things to do down that way as long as they were there so he and Fonda planned to leave by 9 AM.  He came to our bus just before 9 AM to let us know they were close to leaving and that he put an air hose out by the automotive bay so I could fill the front tires on the bus if needed.  Based on the readings from our TireTraker TPMS, however, no adjustment was needed.

We planned to leave sometime after they did but not later than 10 AM.  The main reason for not leaving sooner was to give us time to digest our breakfast, but the other reason was our relatively short drive today to Camp Turkeyville, an RV park on I-69 just north of I-94.  This will be the first time I have been in Michigan, which I certainly consider home, since we left on November 30, 2014.  Turkeyville is only 80 miles from our house, but we will have a full hookup site so we can dump our waste tanks tomorrow morning and not need to use them on the final short drive to the house.

We started getting ready to leave around 9:45 AM.  I shut off the block heater, put Butch’s air hose away, and then took care of the chassis batteries, auxiliary air, and shorepower.  The DD fired right up and I switched it to high idle while it built air pressure.  As soon as the chassis was at ride height and the air dryer purged I pulled onto IN-16 pointing eastbound and pulled into the curb/parking lane.  That was around 10 AM.  I left the engine idling while Linda pulled the car up behind the bus.  By the time we hooked up the car for towing, checked the lights, and pulled away it was closer to 10:20.  I noted that the time was 10:30 AM EDT as we pulled onto US-31 N from IN-16 E.

Traffic was light and we had an easy run up US-31 to US-20 except for the 15-20 MPH crosswind from the WNW.  I also had a very cold breeze blowing into the cockpit by my feet and had to turn the heat up to stay comfortable.  We were an hour into our trip when I finally realized that I had not opened the air supply valve for the shutters on the two front house air-conditioner condensers which are installed in what is normally the spare tire bay.  Those shutters are held open by a spring and held closed by air pressure.  When they are open air can easily find its way into the cockpit.  There is also a mechanical damper that is supposed to regulate fresh air flow to the cockpit, or cut it off completely, but the flexible actuator cable broke some time ago and the damper/cable are difficult to access so it has not been repaired.  Either the cable broke with the damper in the closed position or I taped some sort of cover over the air inlet once upon a time because once I closed the shutters for the A-C compressors I no longer had cold air coming in by my feet.

Traffic was heavier on US-20 eastbound but it always is as it runs just south of South Bend and Elkhart, Indiana, and a bit north of Goshen.  It is still a limited access highway until east of Elkhart, so it moved along up to that point.  There was one stretch between there and Middlebury where major construction was taking place, but we got through that easily enough.  After that it was a nice, rolling, 2-lane highway and we rolled along at 55 MPH except for the occasional town on intersection.  We always enjoy driving through this part of Indiana.

We turned off of US-20 onto I-69 N, crossed into Michigan at 12:53 PM EDT, and pulled into the Michigan Welcome Center five minutes later.  We only had 37 more miles to our destination but we both needed a short stretch break and I wanted to open the air valve for the A-C shutters, which is in the bay under the driver’s seat.  We resumed our trip and exited I-69 at exit 42 around 1:45 PM, crossed over the highway, and traveled the 500 yards to the Camp Turkeyville entrance.  We followed the long, wide, winding entrance road and stopped at the office where Linda got us registered.  They put us in a 50A full hookup pull-through site with easy access that was long enough for us to leave the car hooked up for towing.

We went through our usual arrival routine and then Linda fixed a light lunch of French Country Vegetable Soup and a tofu hotdog on pita bread with mustard and relish.  She also made a pot of coffee.  We connected our WiFiRanger to the RV Park Wi-Fi system but did not seem to be able to move any data so we turned on our Verizon Mi-Fi and connected the WFR to it.

Linda spent the afternoon reading a book on her iPad and I mostly worked on my blog post for April 7, 8, and 9.  I had 14 photos for that post but inserted them into the post rather than put them in a WP image gallery.  I logged into our personal WordPress site, installed WordPress 4.2, and then installed updates to plugins and themes.  Once that was done I uploaded the blog post and uploaded/captioned/inserted the photos and generated the tags.  I clicked the “Publish” button about 7:10 PM.

Linda put dinner on the table about 10 after I finished working.  She made a nice tofu scramble, a dish that vaguely resembles scrambled eggs, and served it with toast and jam, a small glass of juice, and black seedless grapes.

I thought about working on my blog post for April 10th, as it is the last one for which I have photos, but I was too tired to get involved in that tonight.  We pointed our front OTA TV towards Battle Creek and Kalamazoo, found the local CBS station, and watched a couple of episodes of The Big Bang Theory and whatever else was one.  We caught some local weather and decided to enable the diesel burner on the Aqua-Hot, turn the thermostats on, and set the temperatures for 60 degrees F.  The overnight low temperature was forecast to be 27 and it was already 29 when we went to bed.  Welcome to Michigan in late April.

2015/04/24 (F) Touchdown

I awoke at 6:30 AM to an outside temperature of 27 degrees F.  Our coach has several ways it can be heated if we are plugged into adequate electrical power, including three electric toe-kick heaters.  I turned on the Aqua-Hot diesel burner and electric heating element last night before going to bed and left the living room and bathroom thermostats turned on with the temperature dialed back to just under 60 degrees.  I also turned on the Broan cube heater, dialed back the thermostat, and set in on the step to blow into the cockpit.

I got up at 7:15 AM and put on my sweats. It was 60 degrees F on the kitchen counter, but the refrigerator adds some heat mid-coach.  The thermometer on the dashboard read 53.  I turned the thermostats up to 68 and turned on the Aqua-Hot engine preheat loop.  I also turned on the front electric toe-kick heater.  I made coffee and then turned on the electric block heater for the engine.  I checked e-mail and monitored our amperage while I waited for the coach to warm up and for Linda to get up.  We were drawing about 30 A on Leg 1 and 20 A on Leg 2.  On a true “50 A” RV electrical service with a main circuit breaker that functions correctly we can safely draw 40 Amps on each leg, so our usage was not going to trip any breakers.

By 10 AM the temperature was up to 40 degrees, the sun was shining, and it’s was delightfully cozy in the rig.  I got a call from Michele Henry at Phoenix Paint in response to an e-mail I sent her yesterday and talked to her for 15 minutes.  We had planned on a 10:30 AM departure but by the time I connected the sewer hose, dumped the waste tanks, and put the hose away it was 10:45.  We had the bus and car ready to travel by 11AM and pulled out of our site.  We had to wait for a few minutes until someone moved a 5th wheel which they had temporarily parked in the middle of a two-way road while waiting to get into their site.  We finally made our way out of Camp Turkeyville and pulled onto I-69 N at 11:13 AM.

We had an easy run to our house and our wheels “touched down” on our driveway at 12:45 PM.  Even the dirt roads for the last two miles of our trip were in reasonably good shape, which made for a nicer homecoming.  We opened the house, put the cats in their carriers, and took them inside.  I got the bus plugged in and the air shut off while Linda put the batteries back in the water softener and sanitizer and turned the well pump on.  I turned the gas back on for the kitchen and fireplace and then set all of the thermostats up to 65 degrees F.  We unloaded a few things from the bus and then had lunch, after which I sent text messages to both of our children and to Chuck Spera to let them know we were home.

After lunch we unhooked the car from the bus and continued unloading the bus but did not get everything taken off.  I was tired and took a long nap, only getting up when Linda told me it was time for dinner.  We had a Daiya Mushroom and Garlic pizza.  We have used Daiya vegan cheese for a while but did not know they made pizza products until we saw them at the Dierbergs Market in Edwardsville, Illinois.  It had a thin, crispy, rice flour crust (gluten-free), lots of garlic and cheese (of course), and was very tasty.  I wish we could buy them near our house.

After dinner I called Butch to let him know we made it home safe and without any new or reoccurring bus issues.  He had reassembled the driver side steer wheel and discovered that the new brake drums he got from MCI some time ago are the wrong ones, so he is going to have to track down the correct ones next week.

2015/04/25 (S) Return to Regular

Do you remember when OTA TV stations used to break in to programs with special news bulletins or emergency alert tests?  At the conclusion of such interruptions the announcer would say “we now return you to your regular programming.”  Having spent most of 61 years living in stationary dwellings we still consider being back at our house to be the baseline for our regular lives.  The last two years, however, we have spent half of the year, more or less, living in our converted motorcoach.  That fact, combined with the fact that we moved to a new-to-us house just before we started our extended traveling, has altered our perception of what constitutes “regular.”  All we know for sure is that living this dual lifestyle is our new normal and we like it.

Whether living at home or in the bus we have routines.  Part of our “at home” routine is Saturday morning breakfast with our friends from the South Lyon Area Amateur Radio Club (SLAARC) and that is how we started our day.  We took our usual route to South Lyon and were surprised by the extent of the construction work at the I-96 and US-23 interchange.  We knew this interchange was scheduled to be rebuilt starting this year but as of March 1st, when Linda last drove through there, work had not started.  A lot has happened since then, and from the look of things this is going to be a BIG project.

There were a LOT of people at breakfast, 24 by Linda’s count.  It was good to see our friends and ease back into ham radio talk.  The club president, Harvey Carter (AC8NO), had the personalized club jackets we ordered from Sunset Sportswear in South Lyon over the winter so we got those from him after we were all done eating.  The jackets are dark blue with fleece lining and yellow embroidery that looks very sharp.  The left breast says “South Lyon Area” on top and “Amateur Radio Club” underneath.  On the right breast is our first name (in script) on top and our call sign underneath in block letters.

We stopped at Barnes and Noble on the way home to pick up a gift for grand-daughter Katie and found two books that we thought would interest her.  One was on rocks and gems and the other was on snakes, both of which are interesting to Katie.  Both are also an integral part of the desert southwest where we spent the winter.

When we got home I set about the tasks of moving various pieces of technology from the entrance foyer to my basement ham shack/office, reconnecting it to power and our network, and starting it up.  I started up our Linux box but the video driver would not “catch” so I shut it down and restarted it in Windows 2000 Pro, updated the es|et nod32 anti-virus database, and installed three Microsoft updates.  I checked e-mail on my primary laptop, responded to a couple, and then installed updates on all of the websites I manage.  WordPress just released version 4.2 and each new release triggers a flurry of plug-in and theme updates.

Our daughter, Meghan, had arranged for us to come over mid-afternoon to visit and have dinner without the bother and fuss of fixing a big meal.  Minn, the female cat, hid immediately but Inches, the male cat, hung around for a while.  Grand-daughter Katie is working at Pizza House in Ann Arbor where he dad, Chris, has been the general manager for a long time, but she got off work and arrived just after us followed by Chris, who had run out to pick up dinner at Seva.

Our son, Brendan, daughter-in-law Shawna, and grand-daughter Madeline showed up a little later, and Inches promptly disappeared.  Madeline is very sweet and interacts with her two kitties, Gus and Iggy, just fine but our cats, and Meghan’s/Chris’s cats, disappear whenever she comes to visit.  They are just not used to the size, motions, and sounds of a 28 month old.

Seva is a vegetarian restaurant that has been a staple of the Ann Arbor restaurant scene for many years but recently moved out of downtown to a location on the far west side of Ann Arbor.  While not just around the corner from Chris and Meghan’s house it is much closer, and easier to get to, than driving into downtown.  Many of their menu items are vegan, or can be made vegan, and that is mostly what they ordered.  We had a nice visit with excellent appetizers and main dishes, a dozen choices in all, and a nice Riesling wine from Washington State.

After appetizers we distributed the gifts we had picked up for everyone.  Besides Katie’s books Madeline got a “Dr. Seuss” book about deserts and a t-shirt from Marilyn with a design on the front that changes color in the sunlight. Both of our children, who kept an eye on our house for us over the winter and took in our mail, got the following:  A bottle of Red Chile Wine from St. Clair Winery in Deming, New Mexico; a bouquet of pequin chiles from Hatch Chile Sales in Hatch, New Mexico; a box of Prickly Pear Cactus jellied candies and a jar of Prickly Pear Cactus jelly from Organ Pipe Cactus National Monument in Arizona; a bag of Green Chile Pistachios from Eagle Ranch (Heart of the Desert) in Alamogordo, New Mexico; a two box set of olive oil and peach balsamic vinegar glaze from Queen Creek Olive Mill in Queen Creek, Arizona; and a non-stick grilling mat from the “Big Tent” RV Show in Quartzsite, Arizona.  We appreciate what they do when we are away which would be more complicated for us without their assistance.

We enjoy looking for gifts that are unique to the areas we visit and tend to limit ourselves to items that are consumable so no one has to find room to store or display something, at least not for very long.  We saw many wonderful art and craft objects this winter but they present a special challenge beyond simply getting them home.  We are no longer collecting “things,” as we already cannot display or store the stuff we have, and our children are in somewhat the same situation (which is why we still have a lot of stuff instead of them having it).

Then there is the matter of taste.  Both children have their own taste in art and have carefully arranged items for display on their walls and shelves.  As much as we might like something, and think someone else might like it, buying art for other people is fraught with peril because there is an implied expectation that it will be displayed.  If it is displayed but the recipient does do not like it then the gift is intrusive.  If it is not displayed the giver is disappointed and potentially offended.  Better to stay clear of all that by avoiding surprise gifts.  The exception is if we know they are looking for something in particular and we come across one.  In that case it is a simple matter to take a photo with one of our smartphones and message them to see if they want it, making it clear that “no” is an acceptable answer.

Madeline goes to bed at 8 PM so she left (with her parents) at 7 PM.  Both Minn and Inches came out shortly thereafter to have a bite to eat and get the attention they had missed for the last four hours,  We stuck around for another hour which gave us just enough time to get home before it got really dark.  Brendan and Shawna had kept/used Linda’s Honda Civic all winter. They came in two cars and went home in one so that Linda could get the Civic back to our house.  There is a chance that she will have to go into the bakery a day or two this week and I do not like be without transportation, especially when we have a lot going on.

We sat in the living room for an hour reading and relaxing with our favorite iPad apps/games but without the benefit of our natural gas fireplace logs.  I lit them when we got home and they operated for about 60 seconds and then shut off and would not relight.  I turned the pilot flame off and will deal with that tomorrow.  I went to bed, read for a while longer, and then went to sleep.

 

20150416-20 (R-M) MO, IL, IN

2015/04/16 (R) Carthage, MO to Edwardsville, IL

[Note:  There are no photos for these posts.]

I was awakened from a light sleep this morning by a change in the sound of our auxiliary air compressor and the pneumatic systems on the bus.  A valve that whines in a certain way as the system fills with air changed its tune and the compressor ran longer than it normally does and did not shut off.  I got up, turned it off, turned it back on and it finally completed its cycle and shut off automatically.  At that point I was up and wide awake so I got dressed.  Linda was awake by that point too so I suggested that we just get an early start on today’s journey, and that is what we did.  We pulled out of our site at the Coachlight RV Park at 7:30 AM and a few minutes later we were headed south on I-49.  Less than a mile later we looped around the cloverleaf interchange onto I-44 headed east.

The sky was overcast and we ran in and out of fog and mist as we traveled up and down the rolling hills of southwest Missouri with spring in full bloom.  The temperature was cool and the conditions made for easier driving than having a bright morning sun in my eyes.  Traffic was light to moderate for the first 2/3rds of the trip, albeit heavier passing through Springfield and Rolla.  About 200 miles into our trip we stopped at the Flying J at exit 226.  I-44 was now six lanes and we were at the fringe of heavier urban traffic and encountered a center lane closure on a bridge which brought traffic to a halt.  We patiently worked our way through that and a little farther along exited I-44 onto I-270 which became I-255 and took us across the mighty Mississippi River into Illinois, most of the St. Louis, Missouri metropolitan area to our north.

Once we crossed the river and traveled a few miles traffic thinned out but we bumped our way along as the road surface on this stretch of I-255 was very rough.  We exited I-255 onto I-55N/I-70E and then stayed with I-55 when it split from I-70.  It was a good thing, too, as I-70E was backed up all the way to the split with traffic stopped and a sign announcing long delays and advising motorists to seek an alternate route.  A few more miles and we were at our exit for IL-143, crossed over the highway, did a 180 onto the service road, and drove the last mile to the entrance to the Red BaRn RendezVous RV Park just east of Edwardsville, Illinois.

The entrance to the RV Park was a bit narrow but wide enough that I was able to swing in off the service road.  The interior gravel roads were also narrow, and I had to snake past the office, but they turned out to be just wide enough to accommodate an RV our size.  The office was closed but there was a note on the door with our name and site number.  The site had trees on either side that did not appear to be trimmed up high enough but it turned out that they were.

While not a destination park Red BaRn RendezVous is a nice little place in a location convenient to Edwardsville and Glen Carbon, Illinois, where Linda’s sister lives, and the Interstate highways that will get us to my sister’s house in 30 to 40 minutes.  The office building has men’s and women’s restrooms with showers and a small but well equipped laundry.  We had no commitments to visit anyone today and were in early enough that Linda gathered up the laundry and we carried it over to the laundry room.

Linda had some fresh blueberries that needed to be used so she made vegan blueberry pancakes for dinner.  We do not have these very often but they are a real treat when we do.  We were both tired and had headaches, unusual for me but not for Linda, and decided to drive into Edwardsville and find the Walmart.  We wanted to buy a present for Lilly and it gave us a reason/place to stretch our legs.  Back at the rig we located the OTA TV towers, oriented our front OTA TV antenna, and watched episodes of The Big Bang Theory while diddling on our iPads and computers.  I hate to lose a block of potentially useful time but I was not up to working on photos and blog posts and diddling was the best I could manage.

The only “issue” we had with the bus today involved the behavior of the air system.  There are three air pressure gauges in the cockpit—primary and secondary on the dashboard, and auxiliary to the side—corresponding to the three “systems” that operate the chassis (brakes and suspension), and accessories (belt tensioners, radiator shutters, air horns, step slides, and house components).  The air from the main engine air compressor goes through a dryer that removes moisture and then goes to the primary, secondary, and auxiliary tanks.  It sounds simple but it is a bit more complicated than that.  I returned an earlier phone call from Butch and discussed this with him.

As best I understand it (and care to take time to explain it here) a valve, or set of valves, regulates where the compressed air goes and the top priority is the brakes.  The primary tank/system supplies air to the rear brakes and the secondary tank/system provides air to the front brakes (or vice versa).  Until the air requirements of the brake systems are satisfied air does not flow to the suspension or accessories.  Once all of the systems are pressurized they are isolated from one another so that a failure of any component will not affect the other systems.  It is a clever, fault-tolerant design that works well and has stood the test of time.  The components are used on 18-wheelers, fire trucks, and all manner of heavy highway equipment, including commercial buses in passenger service.

When the system is working correctly this is what I normally see when driving.  When the systems are fully pressurized the primary, secondary, and auxiliary air pressure gauges all read ~130 PSI.  The primary and secondary gauges will stay at that pressure unless/until I apply the brakes.  The auxiliary gauge, however, will drop over time due to small leaks somewhere that I have not been able to isolate.  Once the pressure in any of the systems drops to about 90 PSI, which is almost always the auxiliary system, the main engine air compressor kicks in and brings the pressure in all of the systems back up to ~130 PSI.

What I saw for most of the drive today was different, and that is always a cause for concern and makes driving less enjoyable.  All three gauges were showing a loss of pressure and the pressure in all three systems was the same.  The compressor was still working and would kick in at ~90 PSI and bring all three back up to ~130 PSI, so that was good, but the behavior suggested that one or more isolation valves had “stuck” in a position that kept all three systems tied together, which was not good.  Because of the larger volume of air being lost through the leak(s) in the auxiliary system it took a lot longer for the pressure to bleed down and it took longer for the compressor to bring it back up.

About four hours into our six hour trip we stopped for fuel at the Flying J Truck Stop at exit 226.  When we resumed our travel I noticed that one of the gauges (primary or secondary, not sure which) was holding its pressure while the other one continued to drop along with the auxiliary gauge.  An hour after that I noticed that both the primary and secondary gauges were holding pressure while the auxiliary gauge was cycling, and this behavior continued for the rest of the trip.  Thus it appeared that whatever caused the abnormal behavior had self-corrected.  My suspicion is that a stuck valve had gotten unstuck.  Once we were parked and set up the auxiliary air compressor cycled on and off properly, confirming that the isolation valve(s) was(were) once again working correctly.

2015/04/17 (F) My Side

We were up between 7:00 and 7:30 AM, not because we had to be but because we were rested and awake.  We had a quiet, relaxed morning enjoying our coffee and granola and using our iPads to check on the world (L) and work on yesterday’s blog post (me).  We configured the bus to ensure the cats’ comfort while we were away and left at 10:30 AM to drive to my sister’s house in Bridgeton, Missouri.  We stopped for fuel just short of her house and finally arrived around 11:30 AM.

We were greeted by Patty and Maggie, her one remaining dog.  We visited for an hour and then went to a Panera (St. Louis Bread Company) not far from her house for lunch.  We returned to her house to continue our visit and await the arrival of Ryan, Amanda, and Lilly, who showed up a little after 3 PM.  They would have come earlier but Ryan had a routine work-related physical on which his continued employment depended.  To everyone’s relief he passed so everyone was relaxed.  Lilly was initially surprised to see us but immediately gave us a big smile and went to Linda’s outstretched arms.  Lilly is 27 months old and is a cheerful, happy child who interacts easily with whomever is around.

Ryan and Amanda were hungry so at 4:30 PM we headed to El Maguey Mexican Restaurant for dinner.  We had taco salads with beans instead of animal protein and everyone seemed to like their food.  It is Amanda and Ryan’s favorite Mexican restaurant.  Amanda and Ryan headed home with Lilly and we drove back to Patty’s house to wrap up our visit while we waited for rush hour traffic to subside.

Brendan called and Linda got to “chat” with Madeline and then each of us took turns talking to him.  He had received his offer letter from Eastern Michigan University and acknowledged it, so he will start his tenure track assistant professorship in the art history department in September.  The discussions about initial course assignments, however, have already started.  He also mentioned that Shawna’s application for tenure at the University of Michigan Ann Arbor is looking very positive.  Both of those pieces of information were very good news for us.

We took our leave at 7:30 PM and got back to our coach just before darkness settled in.  Having spent a long day enjoying the company of family we settled in to watch a few shows on the local PBS station’s Create sub-channel before turning in for the night.

2015/04/18 (S) LF-M-LH Day 1

Yesterday Linda (LF) talked to Marilyn (M) briefly as we (B & LF) were driving back to the rig from Patty’s house and they (LF & M) agreed that we (LF & B) would arrive at Linda H’s (LH) house around 11 AM tomorrow, which is now today.  (Hopefully the LF and LH designations will help keep straight which Linda I am referring to.  Most of the rest of this post is about today not yesterday.)

We were up this morning at 7 AM and had our usual coffee and granola.  It’s a good thing we will be getting home soon because we only have one day’s supply left of LF’s homemade granola.  It is so good that we have stopped buying commercial granolas because they do not have any taste by comparison.

After a suitably relaxing start to our day I continued plugging away at editing blog posts and selecting/processing photographs to go with them.  I dealt with some e-mails and then we gathered up our stuff and headed to (LH’s) and Marilyn’s house in Glen Carbon, Illinois.  Glen Carbon and Edwardsville flow together to form a contiguous urban area but they are distinct municipalities with Glen Carbon being to the south of Edwardsville.

We are camped just to the east edge of Edwardsville on the edge of a corn field.  The RV park is conveniently located to I-55 and just 10 minutes from LH and M’s house so we were there by 11:15 AM.  LH and M had purchased various fresh ingredients for a salad and after sitting and visiting for a while Marilyn assembled the salad.  There was something going on at the house across the street that resulted in the wife calling the police and three cars/officers being dispatched to the scene.  LH said the husband was himself involved in law enforcement so that added a certain tension to the whole situation as he almost certainly had firearms in the house.

We spent the rest of the afternoon chatting until Marilyn had to leave for a gala fundraiser for a school that her Congregation supports.  We decided to continue visiting with LH and stay for dinner.  LH had a bag of shredded vegan mozzarella “cheese” so we ordered a mushroom and onion no-cheese pizza from Imo’s and she ordered a medium supreme.  I drove into town and picked up the pizzas.  When I got back we added the vegan cheese to ours and heated it in the oven long enough to melt it.  It was very good.

In recent times Imo’s was our favorite pizza (after the demise of the Luigi’s restaurants in the St. Louis area many years ago) but the last time we tried one without cheese it was not very satisfying.  The crust is thin and crisps nicely, the way we like it, and the sauce is slightly sweet and used sparingly, the way we like it, but their normal cheese, a mozzarella and provolone mix, is (apparently) what pulls together the pie’s uniquely fabulous taste.  While the vegan mozzarella was not an exact replacement it made for a very tasty meal, bringing both taste and texture to the pizza.

We needed to do some grocery shopping so we took our leave at 7:30 PM and drove to the Dierbergs supermarket in Edwardsville.  There are three grocery stores at the intersection of IL-159 and Governors Parkway, but Dierbergs was the most likely to have what we were looking for.  Our shopping done we headed east on Governors’ Parkway almost to I-55 and took the service road back to our RV park.  We gave our cats the attention they were seeking while Linda (LF) settled in with her e-book and I worked on the blog post for our two-day visit to Organ Pipe Cactus National Monument.  I also proofread the final draft of the March 2015 issue of Bus Conversion Magazine and sent back my corrections.  I uploaded the blog post and then went to bed to work on the posts for yesterday and today.

2015/04/19 (N) LF-M-LH Day 2

Linda (LF) was up at 6:30 AM, earlier than usual, and I got up at 6:50 AM.  Before I had a chance to start making our morning coffee she pulled up the weather and showed me the radar.  Rain had been forecast to start just after midnight, and continue all day today and into tomorrow, but it appeared that it had not rained last night.  The radar, however, indicated that the rain was on our southern doorstep.  I needed to dump our holding tanks and refill our fresh water tank, so I took care of that while Linda made the coffee and updated her cost-of-camping spreadsheet.

The dump and fill process took me about an hour but we now have enough waste tank capacity and fresh water onboard to get us home with room to spare.  Based on Linda’s data our average nightly cost to “camp” this winter has been about $8.75.  Not bad.  Our average daily cost for our winter in Florida was over $20 which we felt was a very reasonable cost for wintering there.  We drove more miles this winter compared to last, almost double in fact, so we spent the money we saved on camping buying diesel fuel.  Fortunately diesel fuel prices in the central and western states where much lower than the prices in the southeast last year.  They were, in fact, the lowest prices we have seen in years so that was a nice break.

I updated my water usage spreadsheet while Linda got caught up on our personal accounting and bills.  Cell phones and cellular data, in conjunction with the Internet and electronic banking, have fundamentally transformed the full-time and extended-time RVing experience in ways that no one could have imagined 15 years ago.  I had an e-mail from Dropbox that Kate had joined a folder I had shared with her so I sent her a short e-mail updating her on our travel plans.  I also had an e-mail with the final draft of the print version of the March 2015 issue of BCM and verified that the corrections I uploaded last night had been made to my article.  I consolidated my blog posts for March 22 and 23 and finished editing them.  I had just started looking at the unprocessed photos for those posts when it was time to pack up and head to Marilyn and Linda’s (LH) house for the day.

The weather was overcast and gloomy and the rains eventually came, a perfect day to stay inside and eat, talk, and play games.  Marilyn has been making a real attempt at moving to a vegan diet so she prepared tomato soup and black bean burgers for lunch.  We then put the leaf in the dining room table and got out the Mexican Train dominoes game.  We brought hummus and Linda (LH) had made vegan guacamole so we enjoyed those with a few Fritos corn chips.  We also had fresh grapes and toasted almonds to munch on and a couple of bowls of popcorn.  We played 16 rounds of Mexican Train starting with the double 15 tile in the center and ending with the double “zero” (blank) in the center.  It was evening by the time we finished and everyone enjoyed having a whole day to hang out with family and friends with nothing more important to do than play a game.

We left just before 8 PM and drove through Edwardsville to get back to the RV Park rather than get on the Interstates.  There was very little on TV that interested us and we ended up watching an episode of The Man from U.N.C.L.E.  It was a very popular show in its day but is now very dated to the point of being almost silly.

Linda (LF) read and I selected/processed photos for my blog post about our visits to Ajo, Arizona on March 22nd and 23rd.  I got the post and photos uploaded and then went to bed.

2015/04/20 (M) Edwardsville, IL to Twelve Mile, IN

Linda was up a little before 7 AM and I was up a little after.  Today was a travel day, so we did not make coffee or have breakfast.  We were not hungry anyway having had our fill of food, both good and junk, yesterday.  We each had a cup of tea while we got our day started.

We started getting ready to leave around 9 AM and finally pulled out of the Red BaRn RendezVous RV Park at 9:50 AM.  We had about 330 miles to travel to get from Edwardsville, Illinois to Twelve Mile, Indiana.  Since the RV park is just off of I-55 we took I-55 north to I-72 near Springfield, followed that east to I-57 and then took that north to US-24.  We followed US-24 east and moved from Central Daylight Time to Eastern Daylight Time sometime after we crossed into Indiana.  US-24 joined up with US-35 to bypass Logansport, Indiana to its south and then split off to continue east towards Peru.  We picked up US-31 just before Peru and took that north to IN-16 where we headed back west about five miles to Twelve Mile.  It was 5 PM (EDT) when we arrived at Butch and Fonda Williams’ place.  The bus ran well except for a couple of tattletale lights that started blinking briefly towards the end of the trip.  The previous problem with the chassis air systems did not reoccur.

I checked the manual after we got parked and one of the lights was for a chassis battery voltage Hi/Low condition and the other was for the upper and lower 12 V strands of the chassis battery being out-of-balance.  Both conditions, if true, might implicate the Vanner battery equalizer but the first diagnostic step will be to check the circuit breakers.  The next step will be to check all of the battery connections, including the Vanner.  One of the things on my To-Do list is to swap the upper and lower batteries as the “24V” gauge on the dashboard usually reads 29 V and the “12V” gauge usually reads 14 V or slightly less if I have the headlights turned on.

Butch and Fonda had to take his parents to medical appointments in Lafayette, Indiana today and got home just before we arrived.  We did not realize they were there but that was OK; they knew we were coming and we have a nice level spot to park on concrete with a “50 A” electrical connection when we are here.  (It’s a 240 VAC connection with a 50 A RV outlet but we can only draw about 30 amps on each leg.)  Even though we left home on November 30, 2014 Twelve Mile feels like the place where our trip to the southwest U.S. began as we left from here in a caravan with Butch and Fonda on December 3rd.

We were settled in our spot and had our WiFiRanger connected to their Wi-Fi access point when Butch and Fonda either realized we were there, or that we were not going to knock on their door, and came over and knocked on ours instead.  They came in our bus and we talked for over an hour at which point Butch needed to deal with a Facebook group admin issue.  After they returned to the house Linda started preparing our dinner while I checked e-mail and then continued working on this blog post.

Linda sautéed onions, mushrooms, and garlic in a little olive oil and added torn spinach at the end.  She cooked two baking potatoes in the microwave oven and served them with the sautéed vegetables as a topping along with some almond milk jalapeño pepper jack vegan cheese.  A simple but satisfying dish on a cool, clammy evening.  We also had some black grapes with the meal which were tasty and refreshing.  We made two large cups of hot tea and took them to the house where we visited with Butch and Fonda some more.  By 10 PM we were too tired to be good company so we returned to our coach and went to bed.

 

2014/12/01-04 (m-r) Westward Ho!

2014/12/01 (M) Back in Twelve Mile IN

As I indicated in yesterday’s post we are back in Twelve Mile, Indiana for a couple of days before heading on towards the southwest United States.  Butch and Fonda are scrambling to get ready and although there isn’t much we can do to help, we have made ourselves available.  If nothing else we can cheer them on.

We went to bed early last night, tired from our final departure preparations and 270 miles of travel yesterday, and slept in this morning.  Once we were up we had our usual granola with fresh fruit for breakfast and then walked over to Small Town Brew for coffee and conversation with owner Lisa Paul and whoever else happened in while we were there.

Well caffeinated, and pushing 9:30 AM, we checked in on Butch and Fonda.  There wasn’t anything we could help with so we both set up our computers and got online.  Linda paid bills while I updated the spreadsheet I use to track cross-purchase costs.  I hooked up their small Canon iP90 inkjet printer and printed out a copy for Butch and wrote him a check for the balance we owed them.  I showed Linda the MFJ-998 full legal limit antenna tuner that Butch wanted to sell and decided to buy it, resulting in a second check.  We plan to (eventually) use this in our base station, but it was a good enough deal that it was worth buying now and transporting to Arizona and back.  Buying it now also helped out our friends.  I logged in to RVillage and updated our location while Linda walked down to the Post Office two buildings to the west.  (Twelve Mile is a pretty small, compact town.)

Bill and Butch finished repairing Brittiny’s car this past week and she and Rock showed up mid-morning to pick it up.  We visited with them for a while and then Rock headed back while Brittiny visited with her mom.  While they were talking someone stopped across the street and off-loaded a camel.  They had three on the trailer but I’m not sure where they put the other two.  The three wise men, however, were nowhere to be seen.

Although the air temperature was in the upper 20’s it was sunny most of the day, which kept the front of the bus comfortable and well lit.  Given those conditions I decided to work on some projects in the center cockpit area.

First up was (finally) mounting the inclinometer, which turned out to be quite the little project.  I had to remove the mounting bracket from the case in order to attach it to my mounting blocks on the center windshield pillar.  That, in turn, required me to take the case apart and remove the mechanism so I could get to the ‘C’ clips that prevented the bracket retaining screws from coming all the way out of the body.  But I got it apart, mounted, and reassembled, minus the retaining clips.  Really, why would I put them back in?

Linda split the one remaining Tofurkey brand Italian sausage and served it on a couple of hotdog buns for lunch along with a couple of Clementine oranges.  A quick and simple but tasty lunch.

The inclinometer and the compass both have light bulbs in them and needed to be wired up to 12VDC accessory plugs.  The inclinometer already had a power cord but the compass did not, so I got some scrap wire from Butch and fashioned a 2-conductor power cable.  I only have four accessory outlets and three of them were already in use so I attached both power cables to a single plug using wire nuts.  I then dressed all of the wires to make for a neater looking installation that would keep them out of the way and prevent snagging and/or tripping problems.  All of this was a long-term temporary solution; I plan to eventually install a 12 VDC PowerPole distribution system for all of these accessories and hide the wiring to the extent possible or enclose it split cable loom.

I removed the four screws that hold the panel with the 12 VDC house system switches so I could get to the back side of them.  It took a while but I eventually puzzled out how the three air-conditioner switches were wired.  I removed the wire that feeds +12 VDC to the Rear A-C switch and checked for voltage at the loose end of the wire.  There wasn’t any, as expected, so I put a 2 Amp blade fuse in the 12 VDC distribution panel and checked again.  This time I had +13.2 VDC, so everything was good down to that point.  I removed the line and load wires from each switch in turn and checked to make sure the contacts opened and closed the way they should.  They did, so I checked each pin to ground to see if any of them were somehow shorted to ground.  They were not, so the problem was probably downstream from there.  I did not, however, specifically check the bulb circuit for each switch, so I don’t know if there’s a problem there or not.  The bulbs, however, get their power from the load side of each switch, so in the next paragraph the tests I did included the bulbs in parallel with whatever other loads existed.

I tested each load wire for continuity to ground and was surprised that they each appeared as a short.  I did this test with the DC- lead to ground and the DC+ lead to the wire.  When I reversed the leads each wire tested as open.  That suggested there was a diode, or something, acting as a one way current check valve.  I switched the VOM to measure resistance and rechecked each wire.  Where I had previously seen short circuits I saw 0 ohms; where I saw open circuits I now saw about 630 ohms.  Those readings might be a problem, but I don’t yet understand them well enough to know.

The bulbs are incandescent, so their resistance should measure the same in either direction.  If they are 0.6 W they would draw ~0.047 A and have a resistance of ~265 ohms (when illuminated), not the 630 ohms I saw with the red test lead grounded.  Regardless of the exact value, if a bulb was shorted I would see 0 ohms whichever way the test leads were connected.  With the black test lead to ground the 0 ohm readings were, therefore, presumably through the load wires not the bulbs.  If the relay coils were very low resistance (and protected by diodes) they would determine the meter reading in the forward direction, but I would have expected something more than a zero reading.  It seems very odd to me that all three of these loads tested as short circuits in one direction.

I had a weak Verizon 4G/LTE signal at the front of the bus so I tried calling Donn Barnes in Alvarado, Texas.  I got his voice mail and left a message indicating he could TXT message me back.  He did later and I replied that I would call him from Logansport a bit later.  Butch needed a 1/2″ x 1-1/2″ NPT male nipple so Linda and I drove to Logansport to buy one at Home Depot.  While we were there I called Donn and confirmed that he would be home this weekend and that we were still welcomed to visit and spend Saturday and Sunday at his place.  The timing looks like it will work out well as he has to work on Friday and Monday, so we will take our leave on Monday morning.

When we got back to the coach we had some pita chips with hummus while Linda prepared a green salad and started heating some lentil soup.  While we enjoyed the soup she reheated some pita bread and the leftover Koshary.  A small glass of Moscato went nicely with the meal.  After dinner we went in the house to visit with Butch and Fonda for a while and transfer some PDF files onto a flash drive for Butch.  We returned to our coach for the evening at 9 PM.  It was certainly an easier day for us than for Butch and Fonda, but we were tired nonetheless.

We were sitting quietly, reading and writing, when things suddenly got exciting.  Juniper made a sudden movement near the food bowls and I immediately glanced in her direction to see that she had caught a mouse.  We knew at least one was probably still living in the bus because yesterday we found a partially shredded blue paper shop towel in the tray where we store the shore power cords, along with two nuts that had been chewed open.

Juniper is a very skillful huntress but I was surprised that the mouse attempted to get to the cats’ food bowls, which are not in a really safe place for a mouse, with two cats on board.  Juniper is very protective of her catches, so she headed off towards the bedroom, trying to find someplace where we could not try to take it away from her.  We wanted to get it from her and remove it from the coach but our main concern was that she not kill it and try to eat it.

I got a container to try to capture it and Linda managed to get hold of the scruff of Juniper’s neck which caused her to drop the mouse.  It immediately ran further under the bed, a direction from which there did not appear to be an escape path, but we could find no sign of it save a few stool pellets.  I would have needed a much deeper container, like the trash can, to capture it.  Our best guess is that it disappeared into the OTR HVAC duct on Linda’s side of the bed.  Once in there it could travel the length of the bus with impunity, including moving from side to side and between the house and the bay’s.  With any luck it took the hint and moved outside.

Juniper took up her post by the rear corner of the dinette, where she originally caught the mouse, to wait for its reappearance.  A black cat sitting quietly on black tile at night is a pretty effective camouflage.  The problem for the mouse is that it needs to eat and even in its natural (outdoor) environment constantly takes risks to obtain food.

2014/12/02 (T) Tire(d) Pressures

Some nights we sleep better than others.  Last night was not one of our better nights.  The cats were still wound up because of the mouse and I suspect we were anticipating its return as well.  Because neither of us slept well, we slept in this morning.  By the time we were up and dressed it was 8:30 AM.  Linda was pretty sure she had left her gloves and knit hat at the coffee shop yesterday so we decided to go have coffee at Small Town Brew before we ate breakfast.

Linda’s things were there waiting for her to claim them.  We had a nice long chat with proprietor Lisa Paul and invited her to stop over after she closed the coffee shop for the day and get an inside tour of both buses.  We also inquired as to whether she had any post cards of Twelve Mile.  She did not but thought it would be nice to have a few available.  She has a friend, Derinda, who is an artist and thought she would ask her to make a few.  We were interested in one we could mail to our grand-daughter, Madeline, who will be two years old in less than three weeks.

Breakfast was raisin toast and grapefruit, simple but yummy.  We were both dressed to work and went in search of Butch and Fonda to see if we could be of any assistance.  Linda took her computer in the house to transfer some PDF manuals to Butch and then take care of some bakery-related issues.  I used Butch’s MFJ-269 SWR Analyzer to check the VSWR on his 2 meter ham antenna and his (11 meter) CB antenna.  Both antennas are glass mount.  The 2m ham antenna was tuned fairly well, showing a VSWR of 2.1 at the low end of the band (144.000 MHz) and 1.8 across most of the band (up 148.000 MHz).  That is certainly a usable range.

The CB antenna did not test nearly as well.  The CB band is channelized, with channel 1 just below 27.000 MHz and channel 40 just above 27.400 MHz.  At 27.0 MHz the VSWR was greater than 6.0.  It declined steadily as I went up in frequency but was only down to 2.9 by the time I got to Channel 40.  A reading greater than 2.0 (a ratio greater than 2:1) becomes problematic for a transmitter and readings greater than 3.0 are generally unusable.  Both of Butch’s antennas are tunable but we did not take the time to adjust them today.  Butch is taking the analyzer so we can work on the antennas while we are in Quartzsite.

Their bus is parked in between our bus and their house as a consequence of which our WiFi Ranger is not able to pick up their WiFi network signal which is already weak outside the house.  I am having a problem with the unit that has me concerned, but I won’t be able to sort it out until I can get it connected to a working Internet connection.  The problem is that the WFR finds their network and tries to connect to it, requests an IP address, and while it is waiting for a response disconnects from my iPad, which serves as its control panel.  This annoying at best since the WFR and the iPad are only 10 feet apart.

We had lunch at 1:30 PM.  Linda heated up a couple of Thai Kitchen brand hot and sour rice noodle soup bowls.  It had been cold, damp, and dreary all day and we were both feeling a bit chilled so the soup was very soothing in addition to being very tasty.  By 2 PM it was obvious we were not going to get the mid-to-upper 30’s temperatures that had been forecast and there was no advantage to waiting any longer to check/set the tire pressures.  I bundled up, put on my mechanic’s gloves, and set about the business at hand.

Butch turned the auto shop compressor on and I pulled the air hose out and connected it to our hose.  I removed the Pressure Pro sensors from all 12 tires and then worked my way around both vehicles in the same order.  When the sensors have been off for a minimum of one minute putting them back on resets the baseline pressure, which determines the pressures at which you get over- and under-pressure warnings.  I set the bus tires as follows:  front tires to 115 PSI, drive tires to 95 PSI, and tag tires to 85 PSI.  I set the car front tires to 32 PSI and the rear tires to 34 PSI.  I noted that the ambient temperature was 30 degrees F.  I then plugged in the Pressure Pro receiver and repeater and checked the pressures they were reporting.  The four car tire readings were essentially identical to the known pressures in the tires, but the sensors on the eight bus tires all registered low, in one case by 6 lbs.  As I indicated in a previous post I think the batteries are just about drained and are giving tire(d) pressure readings.  I know that I am tired of the discrepancies as I count on these readings to tell me it’s OK to drive or I need to add air to certain tires.

Bill and Bell showed up in his custom car hauler while I was working on the tires.  Bill and Butch worked on some stuff and Bell helped Fonda load food and sundries onto the bus.  Lisa Paul showed up for a brief visit and tour of both buses.  See also brought a postcard that her friend Derinda made.  It featured the building that houses Lisa’s Small Town Brew coffee shop.  Linda is going to post it to Madeline in the morning so it has a Twelve Mile, Indiana postmark.  It will be the first of what we hope are many such postcards from far away exotic places.  Being almost two years old we hope these mementos will provide a tangible connection to us while we are traveling.  I know her parents will use them as learning opportunities.

Linda and I took showers in the house to minimize the use of our stored water and waste tank capacity.  The six of us then drove down to The Old Mill restaurant just west of town for an earlier than normal dinner.  The restaurant also allowed us to use their dumpster to dispose of our accumulated household trash.  That was nice because Butch and Fonda had already suspended their dumpster service for the winter.

When we got back from dinner we got online and checked the weather forecast and road conditions along our planned route.  Bill had recently driven I-70 west of Indianapolis and strongly advised us to avoid going that way.  Our check of the INDOT website confirmed that we were well advised to avoid Indianapolis altogether.  We settled on SR-16 east to US-31 south to US-24 west to I-57 in Illinois.  From there we will take I-57 south to Mt. Vernon, Illinois where we will overnight at Wally World (Walmart).

Bill and Bell said they would be back in the morning to see us off (“watch this thing launch” is how Bill put it) and took their leave.  We hung out a while longer trying to be useful but mostly providing moral support and comic relief until it was time to winterize the plumbing.  Butch hooked up a line from his big shop air compressor, ran it through a pressure regulator, and attached it to the main plumbing line at the surge tank and pump.  Just like an RV he used air pressure to drain both water heaters and then had us open each fixture in turn and let the air blow the water out and down the drain.  We then filled the traps and toilet tanks with potable RV antifreeze.  The reason for using potable antifreeze is that it will eventually end up in the septic tank and drain field.

We finally retired to our coach leaving them to finish up some last minute things before retiring to their coach for the night.  We had some very tasty red grapes for dessert (and a couple of cookies) while we studied maps for our next few days of travel.  We had not really looked at them carefully before now and were surprised to find that we will not be in either Kentucky or Tennessee.  We had presumed that we would be, but I-57 runs into the extreme southwest corner of Illinois and then crosses the Mississippi River into Missouri, ending at I-55 in Sikeston.  From there we will continue south into Arkansas on I-55, which stays on the west side of the Mississippi river, until we intersect I-40 west of Memphis and head west towards Little Rock.  Thus we will never enter Kentucky or Tennessee and we will not drive through Memphis; at least not on purpose.

Fonda has to run to Logansport first thing tomorrow and while she is gone we will prep our bus for travel, hitch up our car, and give Butch whatever assistance we can.  We plan to be on the road by 10 AM and safely parked at the Walmart in Mt. Vernon, Illinois well before dark.

2014/12/03 (W) Finally On Our Way

We were up around 7:45 this morning anticipating a 9 AM departure even though we knew that was unlikely.  I turned on the Aqua-Hot engine pre-heat pump to start warming the engine.  There was a dusting of snow on the ground and on our car; a sure sign that our departure had been delayed long enough.

Bill and Bell arrived a little after 8 AM so we invited them into the coach and chatted for over an hour while Butch and Fonda got their morning organized.  Fonda left for her run to Logansport at 9:15 AM followed by Bill and Bell at 9:25 AM when they decided they needed to go to Logansport to get breakfast.  Fonda returned at 9:50 AM and we started making our final departure preparations.  We had hoped to leave by 10 AM but suspected that was optimistic.  It’s Butch and Fonda’s first extended use of their converted coach and they have had a lot to do to get ready to leave.

We straightened up the interior for travel as soon as Bill and Bell left so all that remained for us to do was unhook the shorepower cord and store it, start up the main engine, move the bus across the street, and hookup the car for towing.  We can do all of that in 15-20 minutes if absolutely necessary, especially in warmer weather, but it typically takes a half hour.  We do not like to rush this process; it’s important that we do it correctly each and every time.  It is also a commonly understood etiquette among RVers that you do not try to chit-chat with, or otherwise disturb, fellow road warriors while they are hitching something up.

Butch & Fonda's MC-9 getting ready to depart Twelve Mile, IN.

Butch & Fonda’s MC-9 getting ready to depart Twelve Mile, IN.

We were idling and ready to go by 10:25 AM but Butch had to make some final adjustments to his toad towing/braking setup.  Bill and Bell were back in time for Bill to help and Bell to take pictures and give us a good send off.  We pulled out a little after 11 AM and headed east on SR-16 with Butch in the lead but only got to the edge of town before Butch pulled off the road.  We pulled off behind him and Bill pulled off the on the other side.  We had noticed that their bus was smoking but they realized something was wrong before we could even call them on our 2m ham radio.  It wasn’t the engine; the brakes on the toad were partially engaged and he could feel the drag.  He readjusted it and we were on our way again, this time for good.

The trip to Mt. Vernon, Illinois was an easy and uneventful run.  From SR-16 we turned south on US-31 and picked up US-24 westbound.  We took this same route in June 2013 when we left Twelve Mile headed to the state of Wyoming so we knew it was a good route for us.  We had to slow down going through small towns, but that gave us a chance to catch a glimpse of these quaint little places.  A couple of larger towns had stop lights, but mostly we were able to keep rolling.

We stopped at a Pilot Truck Stop just west of I-65 for a quick walk-around and so Fonda could take the dogs out.  We continued west on US-24 into Illinois and eventually got to I-57 where we headed south.  We saw occasional construction signs but very little construction and did not incur any delays.  Butch lead most of the day and we just followed along with generally light traffic.

We stopped at the rest area just north of I-70 and took a stretch break, after which we took the lead.  A few miles later we got to the construction on the short stretch where I-57 and I-70 run together.  We had to drive 45 MPH but rolled right through.  After the construction zone we took the center lane knowing that I-57 would split to the left from I-70 and continue southbound.  Slow traffic is often worse than fast traffic as the cars end up bumper-to-bumper leaving no space for larger vehicles to change lanes.

Following the directions on our GPS we took exit 95 for Mt. Vernon, Illinois, drove a quarter mile, and turned left onto a road that ran down the west side of the Wal-Mart property.  Linda had called ahead and been told it was OK for us to spend the night in their parking lot.  The first two access drives, however, had crossbars at 12 feet so we could not turn in. The third driveway was for delivery trucks so we turned in there and headed back towards the north end of the lot by Ryan’s as Linda had been instructed on the phone.  There were signs posted prohibiting semi-truck parking so we parked temporarily while Linda went in to check on the situation.

A women at customer service confirmed that we could spend the night and asked that we stay near the periphery of their parking lot away from the main doors.  No problem.  The lot we had pulled into was not the Wal-Mart lot and was a little tight but were able to extricate both coaches without unhooking our toads and moved them to the northeast corner of the adjacent/connected Wal-Mart parking lot.  I leveled up as best I could, shut the engine off, and then closed the various air valves and switched the chassis batteries off.

The house batteries were at an 89% state of charge (SOC) when we arrived.  We locked the bus and went for a walk around the east end of the building to scout out an exit route.  We stopped in the store and bought a bag of Fritos and some popcorn oil.  When we got back to the coach I started the diesel genset and turned on two of the electric toekick heaters while Linda used the induction cooker to prepare vegan burgers for dinner.

After we had eaten Linda and I sent TXT messages to several people.  We then went over to visit briefly with Butch and Fonda and look at maps for tomorrow’s leg of the trip.  When we returned to our coach we noticed that the generator had stopped running.  Not good.  I was able to restart it but each time it shut down, so I got Butch to come look at it.

There’s a solenoid that holds a fuel valve open and we thought that might be the problem, but it wasn’t.  We checked the level of the oil but it was OK.  I started it again and Butch noticed that the squirrel cage fresh air blower was not turning so I shut the engine off.  Linda had been watching the gauges inside and said the water temperature was very high (off the end of the scale).  Butch checked the blower to make sure it wasn’t stuck. I traced the wiring back to a panel with a couple of circuit breakers and one of them was popped.  I reset it and restarted the engine and the blower came on.  Linda reported that the water temperature immediately dropped.  We suspected, but did not confirm, that the same breaker controlled the power to the large squirrel cage blower for the radiator, which is located in the inverter bay on the other side of the bus.  I let it run for another hour and brought the house batteries up to 95%.  It ran fine with normal water temperature and oil pressure so I think we found the problem and fixed it.

Linda read while I changed most of the clocks to Central Standard Time.  I turned off the electric heating element in the Aqua-Hot to unload the GenSet and then shut it down for the night.  I dialed the three Aqua-Hot thermostats back to 15 degrees C (59 degrees F) and turned on the Diesel burner.  It is only supposed to get down to 32 degrees Fahrenheit overnight but Linda put an extra blanket on the bed since we will not be using the electric heating pads as they would draw too much energy from the batteries.

It was a long day but largely uneventful except for the beginning and the end.  But all’s well that ends well, and this day did.

2014/12/04 (R) Roadside Repair

I was awake at 4:30 AM and got up to check on the SOC of the house batteries and turn on the Aqua-Hot engine pre-heat pump.  The batteries were at 68 SOC.  They were at 95% when I shut the generator off around 9 PM last night, so they had dropped 27% percentage points in 7.5 hours, a rate of 3.6 percentage points per hour or 10 percentage points every 2 hours and 45 minutes.  We did not go out of our way to minimize loads, leaving some night lights on (DC), the Aqua-Hot (DC), and the main inverter loads (refrigerator, auxiliary air-compressor, microwave clock, outlets with chargers, etc.). At that rate it would take just under 14 hours for the batteries to drop to a 50% SOC, starting from 100%.  I was satisfied with the performance of the system and went back to bed.

It started to rain off and on around 5:30 AM, the first sign of a wet day.  I got up to stay at 7:15 AM and got dressed.  I checked the SOC of the house batteries and it was 58%, so it had dropped another 10% in 2 and 3/4 hours, consistent with the 4:30 AM data.  I started the generator to provide power for hot water, lights, and additional engine pre-heating.  It would also start to bring the SOC of the house batteries back up before we started driving for the day, although the Zena power generating system on the main engine should be capable of recharging them in a couple of hours while we are driving.

Since we were not leaving until at least 9 AM we decided to have a light breakfast of raisin bread and grapefruit.  After breakfast I powered up our Verizon Mi-Fi device, got my laptop connected to it, e-mailed yesterday’s blog post to myself (from my iPad), and then checked my e-mail (on my computer).

We had the coach straightened up and ready to go well ahead of our departure.  Around 8:45 Butch indicated that they would be ready to go in 15 minutes.  That was all the time I needed to get the car ready to tow, switch the coach batteries on, open the various air valves, shut off the Aqua-Hot pre-heat loop, and start the main engine.  With the main engine running I turned off all of the loads on the generator, let it run unloaded for a few minutes to cool down, and then shut it off.

We pulled out at 9 AM and worked our way around behind the store and back out the unblocked entrance we came in yesterday.  Instead of turning on Broadway to go back to the Interstate we crossed over and pulled into the Pilot Truck Stop so Butch could top off their fuel tank.  We did not need fuel yet but I pulled in right behind him so we were positioned to pull out together.

We were back on I-57 headed south by 9:25 AM with Butch in the lead.  We ran at 60 MPH through light rain and fog with overcast skies all the way to the end of I-57 at I-55 near Sikeston, Missouri, where we continued south towards Memphis, Tennessee.  We eventually crossed into Arkansas and out of the rain, although the cloudy skies continued.  About 25 miles north of the junction with I-40 Butch called on the radio to let us know that he needed to get off the road at the first safe place I could find.  His air pressure had dropped to 60 PSI and was not building.  A couple of miles later I pulled off onto the shoulder of an entrance ramp and he pulled off behind me.  The brakes and suspension most highway buses are air-powered.  Without proper air-pressure the bus cannot be driven.

The pressure in the system was holding which indicated a supply issue rather than a leak.  The usual suspect in this situation is the “governor” (or less likely the unloader valves) on the main engine air-compressor.  Butch had a spare governor in his parts kit but we were not in an ideal spot for changing it.  He decided instead to hook up his portable air-compressor to his air system auxiliary fill connector.  He put the portable air-compressor in the bedroom at the rear of the bus and had Fonda run the air hose out the passenger side window were I took it and zip tied it to the side radiator grill.  Butch then ran it through a small access door by the passenger side rear lights and connected it to the fill valve.  The portable air-compressor is an AC powered device, so Butch had to start their generator to power it.  It gradually built the pressure to 100 PSI.  The pressure was holding so Butch dial it up to 110 PSI.  He left the portable air-compressor on for the rest of the trip and allowed us to get back on the road, making this a very clever emergency roadside fix.

After a 20 minute delay we pulled back onto I-55 and finished the run to I-40 with heavier traffic.  We exited onto westbound I-40 in West Memphis, Arkansas and completed the 38 miles to Forest City, Arkansas without difficulty.  We negotiated a tight turn onto the street where the Wal-Mart was located but had an easy time getting in at the far west entrance.  From there we pulled up parallel to a north-south curb that ran the length of the west edge of the parking lot.  We leveled up the coach (using the air springs), shut down the engine, and went through our usual dry-camping arrival routine.

As soon as we were set up Butch was back looking at his main engine air-compressor and then on the phone with Luke at U. S. Coach in New Jersey.  He decided to change the governor as it couldn’t do any harm.  I helped him (as best I could) but once the new governor was installed the compressor still would not build air pressure.  The unloader valves were the next most likely (easiest to fix) culprits, but neither of us had the parts.  There was an O’Reilly’s Auto Store across the main road from the Wal-Mart so we walked over there.  They did not stock them either, but at least we got some exercise.

The house batteries were at 78% SOC when we arrived which disappointed me as I expected them to be at least at 88% like they were yesterday at the end of our drive.  We were on the inverter from the time we started up at 9 AM until I turned the generator on at about 3:30 PM.  At our normal rate of 3.6 percentage points per hour we would have been at ~72% SOC without any charging from the ZENA system, so 78% did not seem very good to me.  It appears that I am going to have to adjust the charge voltage up somewhat on the ZENA power generating system as it should be supply enough current to run any AC loads while traveling (mostly the refrigerator) and fully recharge the house batteries.  I let the generator run through dinner until bedtime.  It brought the SOC back up to 91% with the charger in float mode supplying 10 Amps of current at 26.3 VDC.  Once the charger is in float mode it can take a surprisingly long time to finishing bringing the batteries to full charge.

Some weeks back Butch bought a grandfathered Verizon unlimited data plan on Ebay using the Assumption Of Liability (AOL) process.  He also picked up a used phone and a used Jetpack MiFi device.  Both devices can use the SIM card, but he had not had a chance to connect the MiFi through to the Internet.  We removed the card from the phone, installed it in the MiFi and powered it up.  It found a strong Verizon 4G/LTE signal right away.  The menu gave us the password and we were able to connect his laptop computer and my iPad.  He started searching the web while I downloaded e-mails.

Linda and Fonda had walked to the store to buy a few things.  When they got back we chatted for a bit and then went back to our coach.  Linda made popcorn for me (she wasn’t hungry) and we relaxed for a while before going to bed.

 

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. 

 

20141030-1102 Fixing Buses in Indiana

2014/10/30 (R) To Kokomo We Go

Well…sort of.  Our actual destination was Maple Grove Distributors in Galveston, Indiana, which was in the general direction of Kokomo, but not as far.  (It’s pronounced “gal VES ten” with the emphasis on the second syllable.)  The tie rod ball ends that Butch ordered had finally come in and he wanted to get them early this morning so that: 1) We could get back and take advantage of a relatively nice late October day, and 2) He would have them for tomorrow when the weather is forecast to be lousy and thus a good day for inside work such as fabricating ride height linkages.

PS rear corner bedroom cabinet with slot in door for TV/monitor wires.

PS rear corner bedroom cabinet with slot in door for TV/monitor wires.

In spite of the nice weather I spent most of the day working inside my bus, stopping occasionally to help Butch with something.  I don’t have a lot of outside projects at the moment, or at least none that I felt like working on, and I really wanted to get the bedroom TV cabinet taken care of.  As with the front TV cabinet that I worked on for the last couple of days, the bedroom cabinet once housed a 19″ CRT TV set and a VHS tape deck.  I removed those in late 2011 while the bus was at Phoenix Paint and had Jaral Beaty make doors to cover the openings.  Once those doors were installed, I mounted 22″ diagonal, 16:9 aspect ratio, LCD/LED flat panel TV/monitors on each door. The power and signal connections, however, were inside the cabinets, so for the last couple of years the cables have come out of the bottom/rear of the TVs and under the bottom edge of the doors and into the cabinets.  This arrangement prevented the doors from being closed, even though they had spring loaded ball catches, so we have held them closed with a couple of pieces of bright green Frog Tape.  The tape is sticky enough to hold the door closed but does not seem to leave any reside even after being in place for a while.

The wires from the TV/monitor pass through the slot in the door so the dorr can be closed and latched.

The wires from the TV/monitor pass through the slot in the door so the dorr can be closed and latched.

As with the front TV cabinet door, I created a horizontal slot behind the TV, positioned to allow the cables to come down out of the back of the TV and bend gently through to the inside of the cabinet.  I removed some unneeded cable and coiled up other cables and secured them with zip ties that have a mounting tab with a hole for a screw.

My two outside projects were brief.  I got back under the front of the bus between the front tires and unbolted the ride height linkage.  It unbolted from the ride height valve lever arm easily but not from the axle bracket.  Fonda got a can of Cyclo Breakaway and some paper towels for me, but even after spraying the nut and letting it sit it would not come loose.  I am not the strongest guy in the bus yard so I put some more muscle into it and broke the bolt off with the nut still stuck tight to it.  The other half of the bolt then slide out easily.

As long as I had my wrenches out I slide under the rear end of the bus to see if I could free a couple of wires for the auxiliary braking system that were pinched under a mounting pad for the rear bumper fascia.  The stud had a Nylok nut on it that was barely threaded onto the stud.  The reason, I guessed, was the stud was at an angle that made it difficult to get a socket and ratchet on it.  I was able to loosen/tighten it using a universal (swivel) adapter between the socket and the ratchet.  While I was under there I noticed a second stud with a barely threaded Nylok so I tightened it as well.  One of the things you have to watch out for on a used RV is all the work that other people have done ‘just well enough’ to get it ‘out the door’ without something falling off in the parking lot.  These are always things that are hidden and relatively inaccessible, which is why they were not done correctly or completely in the first place, but the assumption is you will never see them.

My other inside project was to separate the load wires for the lighted entrance handle and the patio light and put them on separate switches.  It turned out that the front most switch just inside the entrance door (next to the passenger seat) was supplying 12VDC power to three circuits, the two just mentioned and a third one that, as of this writing, is still a mystery in that I was unable to determine anything that was being controlled by those wires.  The first (front) switch now controls only the lighted entrance handle, the second (middle) switch controls only the patio light, and the third (rear) switch controls…well, I don’t know what it controls but it definitely puts 12VDC power onto a wire that goes somewhere.

I assisted Butch briefly in locating their front fan-coil heat exchanger relative to the bay where the coolant lines will go.  Later in the day I helped him position the front suspension of their coach to the MCI specified spacing for the air springs so he can fabricate the ride height linkage to the correct length.

I needed a few parts for projects I might want to work on tomorrow so I left at 7 PM and drove to the Home Depot in Logansport.  That also gave me a chance to call Linda and chat about cell phone data plans.  I got back to Twelve Mile at 8:30 PM.  Butch and Fonda were already having their dinner so I went to my bus and made a salad.  After I cleaned up the day’s food utensils I installed the 6-outlet surge protected adapter in the AC duplex outlet in the bedroom TV cabinet.  That completed my work for the day and I returned to the house, visited briefly, and retired to my room to check e-mail, offload photo files from my camera, and write this post.

2014/10/31 (F) Boo! Snow (Boo)

After a relatively mild October the weather decided to turn more seasonable just in time for Halloween.  I was originally going to title this post “Foot Pounds and Gigabytes” but decided to acknowledge All Hallows’ Eve instead, along with the dramatic change in the weather.

A couple of days ago I bought a torque wrench from Butch that is adjustable up to 600 foot pounds, which is the kind of torque needed to tighten and loosen the lug nuts on our bus wheels.  It’s a very big torque wrench; over three feet long.  I need to buy a compatible socket to go with it.  Today was also the last day for the Verizon and AT&T double your data plan promotions, so I planned my day to put me in Elkhart, Indiana while one of the corporate stores was still open.

I got up around 8 AM and spent 45 minutes doing some preliminary packing after which I went out to my coach and had breakfast.  We had snow flurries around 9 AM this morning and did not work outside today save the few minutes I spent adjusting the air pressure in the tires of my Honda Element.  Today was mostly about shopping.

I got a cup of coffee from Small Town Brew and then we headed to Logansport where we did most of our usual circuit:  NAPA Auto Parts, O’Reilly’s Auto Parts, Rural King, Aldi’s, and Walmart.  (The only regular place we did not go was Home Depot.)  My only purchase was a 12VDC dual outlet with a mounting flange that I found at O’Reilly’s.  I plan to use it to create power connections for the GPS and TPMS receiver.  (I realized later that I should have bought three of them as I also need to supply power to the DVD camera/recorder up front and the TPMS repeater which I plan to mount in the rear TV cabinet.)

We got back around noon and I spent the next couple of hours straightening up the inside of the bus and packing everything that was going home with me.  Around 2:45 PM I finished packing the stuff I had in the guest bedroom and began loading the car.  I wrote up a list of things we owed each other money for and, as I expected, I owed Butch more than he owed me.  (He tends to order things we need on his accounts and I pay him back.)  I bought a Variac from him, added it to the list, and put it in the car.  Fonda has been working on a wedding dress for their daughter Gene for quite some time and was done except for some trim, so I got to see it before I left, which I did at 3:15 PM.  It was very nice.

I had located a Verizon corporate store on US-33 just south of US-20 which was on my normal route home.  I arrived at that intersection around 4:45 PM and first stopped at the Burger King next door for some French Fries.  The Verizon sales associate, Hector, claimed to know nothing about the double data promotion and insisted there was no such thing available.  I called Linda from their parking lot and we discussed what to do as today was the last day for the promotion.  She had checked our account online last night, and although we could change our monthly data allowance online (for a price, of course) there was no information about the promotion available there either.  Very strange considering how much this has been in the media all month.

Linda was stuck in traffic coming home from the bakery so we chatted while I made my way over US-20 to CR-17 (IN) to I-80/90 (Indiana Tollroad) to the I-69 exit where I had to pay my toll.  Traffic on her end had also loosened up by then so we ended our call.

My entire trip home was in some form of precipitation; mostly rain but occasionally sleet or snow, with very strong and gusty winds from the north that made for somewhat more difficult driving.  It also made it difficult to judge the effect of the adjusted tire pressures on handling although the shimmy seemed to be gone.  I stopped at the Michigan Welcome Center on I-69 and unpacked some of the food I had with me.  I stopped again at M-60 for coffee at McDonald’s and fuel at the TA/Shell station where Regular gasoline was $2.929.  It’s been a long time since we have seen gasoline prices below $3/gallon.  That was my last stop before arriving home at 8:45 PM.  The last few miles were through moderate snow and the strong winds had coated the north facing side of trees and road signs.

Linda helped me unload the car and get everything into the house.  I gave Butch a call to let him know I had arrived home safely and we chatted briefly about bus projects.  I took a shower and went to bed where I finished this post before 11 PM and went to sleep.

2024/11/01 (S) Words

Although we were both very tired we did not sleep well last night.  We awoke early to find a thin covering of snow on our rear deck and over parts of our yard with the temperature in the upper 20s.  We went to our SLAARC ham radio club breakfast this morning anyway, the first time in several weeks for Linda, and there was a good turnout.  Those members who came from east or south of us did not have snow on the ground.

When we got back to our house Linda worked at her desk on our personal finances while I worked at the dining room table on e-mail, websites, and bus project documentation.  Our son and daughter-in-law showed up around 3:30 PM with their daughter.  They had a baby shower to attend in Detroit and Madeline was spending the night with us.

Linda had given me the heads up that Madeline’s vocabulary had increased significantly since I last saw her and that certainly proved to be the case.  She finally had understandable words for many things including the counting words from one to ten.  She is now 22-1/2 months old and is a very active and busy little girl.  We played with lots of different toys, including a new little Thomas The Train locomotive that Grandma Linda bought for her.

We had dinner between 6 and 6:30 PM.  Madeline had mock chicken tenders with broccoli, cauliflower, mandarin orange segments and sliced strawberries.  Linda and I had yummy homemade chili that she had been cooking in the crockpot most of the day.  I played with Madeline after dinner while Linda cleaned up the dishes and then joined the fun.  Nighty-night is her current pre-bedtime game, but by 7:15 PM she was tired enough let Linda get her into her pajamas and then sit quietly while I read a couple of story books to her.  As always, she went to bed without a fuss.

Once Madeline was asleep Linda read and played online word games with friends and relatives and I continued working on my bus projects list, light bulb inventory, and reconciliation of purchases that Butch and I have made for each other.  By 10:45 PM I was tired and ready to do something else so I climbed in bed and worked on this post.

2014/11/02 (N) An Extra Hour

At 2 AM EDT this morning it was suddenly 1 AM EST so when Linda got Madeline out of her porta-crib at 8 AM, according to the clocks in our house, it was officially 7 AM.  We all slept well last night and Madeline woke up well rested and in a pleasant mood.  She enjoys her meals so before any playtime we had breakfast of toast and juice and fresh fruit.  Brendan called around 9 AM to see if we could keep her until after her afternoon nap as he and Shawna had professional work they needed to concentrate on.  I suggested they come for an early dinner and they agreed.  Linda checked her ingredients on hand and then agreed to make her seitan stroganoff served over rice.  This is one of my favorite vegan dishes and a standard ‘go to’ when we are having non-vegan company for dinner.

You cannot have too many bows in your hair, apparently.

You cannot have too many bows in your hair, apparently.

We played with Madeline all morning and she was a very busy girl.  She has understandable words for a few things and a much richer, if somewhat secret, vocabulary that she takes great delight in using.  She knows the names of her basic colors and has started to get the idea of counting.  She enjoys building tall structures with her Lego blocks and is still fascinated with the organ.  Running around the island in our kitchen is another favorite activity; sometimes chasing, sometimes being chased, and sometimes holding someone’s finger.

I got a TXT message from Chuck asking if I was back in town and had time to talk.  Linda let me take a break from playing with Madeline so I could call him back.  He has been working on their bus and wanted to bring me up to date on his projects and get caught up on my projects and timeline.

Our other grand-daughter, Katie, is up in the U. P. with Chris (her dad) and Meghan (our daughter) visiting Northern Michigan University in Marquette.  They visited the Pictured Rocks National Lakeshore yesterday and made it out to Castle Rock.  This evening they had a banquet to attend and tomorrow she has an interview for a scholarship.  Katie is interested in animals and wants to study zoology.  NMU is one of the few universities that offer a true zoology major rather than a biology major with an emphasis in zoology.  It may sound like a distinction without a difference, but it is an important distinction to Katie.  Katie is a serious young lady who has done well in school and will certainly represent herself as such during the interview.  We are excited for her and hope she is successful in obtaining this merit-based financial support.

By 11:30 AM we were anticipating lunch and Madeline requested pizza.  We happened to have an Amy’s Roasted Vegetable pizza in the freezer (our favorite) so Linda preheated the oven and baked it on our pizza stone.  We sat down at noon and enjoyed our pizza accompanied by seedless red grapes.  We were all full by 12:30 and Madeline was showing signs of being ready for her nap so Linda helped her wash her hands and face and then got her settled in her porta-crib.  Madeline enjoys sleeping almost as much as eating and went to bed without any fuss.

The cats, who had retreated to the basement this morning as soon as they heard/saw Madeline, are keenly aware of when she is eating and sleeping.  Once we have her in her high chair at the table we usually open the safety gate at the top of the basement stairs so they can come up.  Both of them did and walked around under the dining room table, apparently aware that she was not mobile.  They eventually went back downstairs but came back up once she was asleep.  We decided to leave the door to the middle/blue bedroom open about six inches to see what the cats might do.  Jasper immediately turned around and went back downstairs but Juniper stuck her head in the room, probably got sensory overload, and also left.

Linda needed a few grocery items and went to Meijer’s in Brighton where she topped up her gas tank for $2.919 a gallon.  If only the price of diesel fuel would pull back to corresponding levels.  It has dropped but not by the same amount.  I stayed home and worked on my bus projects spreadsheet.  When Linda got back with batteries I changed all of the clock batteries and reset the time.

Brendan and Shawna arrived at 3 PM just as Madeline was waking up from her nap.  She was thrilled to see her parents, of course, as they were thrilled to see her.  It was a beautiful, if somewhat chilly, day and they got her coat, hat, and mittens on and played in the yard while Linda started preparing dinner while I cleared the table of my computer and papers and set it for the meal.  We sat down to eat at 4:15 PM and started with a nice salad of chopped greens and cabbage, an Asian dressing, and crispy Asian noodles.  The main course was the seitan stroganoff served over white rice and accompanied by roasted Brussels sprouts and a sliced multi-grain baguette.  The adults had a small glass of the Leelanau Cellars Witch’s Brew, a seasonal mulled (spiced) red wine.

After dinner Brendan and Shawna began the process of getting ready to leave which includes delay tactics on Madeline’s part and their response to them which is always gentle but persistent.  They were out the door at 5:30 PM and by 6 PM we had cleared the table, rinsed the dishes, loaded the dishwasher, and picked up the few toys that were left out in the living room.  Although the clock said 6 it felt like 7.  As hard and as long as I have been working on bus projects, I am surprisingly tired after spending a whole day with Madeline.  I opened the safety gate and Jasper came upstairs right away, eager for our company and attention.  He curled up in my lap while I worked on this post.

We watched Inspector Lewis (streamed), the first TV program I have watched in quite some time.  Part of the PBS Masterpiece Mystery series, it is a really excellent production.  I did some online research on 2m/70cm ham radio antennas and dual (co-phased) CB antennas but did not come to any conclusions about what to get.  The problem remains the same; I cannot put anything tall on the roof of the bus and even if I wanted to I have little-to-no access to the underside of most of the roof.  The fact that the lower roof sections in the front and rear are part of the front and rear fiberglass caps just complicates matters even more as they do not provide a conductive path or ground plane.

 

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.

 

2014/10/08-15 GLCC and Bus Work

2014/10/08 (W) Rally Ho!

Today was a travel day so I had a light breakfast and went to the Small Town Brew for a cup of coffee rather than create a mess making my own.  I donated $2 for this cup and did not have a refill so the three cups I consumed over the last two days averaged out to $1 each.  I spent most of the morning helping Butch investigate possible routes for the engine preheat plumbing for their new International Thermal Research (ITR) Oasis Combi diesel-fired hydronic heating system.  I also adjusted the front bus tire pressures and all four of the car tire pressures.

As noon approached I switched to departure mode.  I changed out of my work clothes into something cleaner and more comfortable for driving, finished packing all the stuff I had in the guest bedroom, and loaded it into the bus or the car.  I targeted a 1 PM departure.  Butch had to go to town so we said farewell until Friday and he took off.  By the time I started the bus, pulled it across the street, moved the car over, hooked it up for towing, and checked the lights (with Fonda’s help) it was closer to 1:30 PM than 1:00 PM.

The drive to Elkhart was pleasant and uneventful.  The speedometer sat on zero for the first quarter of the trip, bounced around for the second quarter, indicated 85 MPH (max speed) for the third quarter, and settled in to something like the correct speed for the final quarter.  This is the way it had behaved for quite some time before it got unplugged so this confirmed that it did not work correctly and needed to be replaced.

I took SR-16 east to US-31 north to US-20 east to CR-17 north.  CR-17 becomes MI-217, the Michiana Parkway, which ends at US-12.  I took that west to Old M-204 west and followed it past Phoenix Paint back into Indiana where it becomes SR-19 south.  I turned east on CR-4 and a mile later turned into the entrance to Elkhart Campground on the south side of the road.  This route is at least 15 miles longer than necessary.  There is an exit for SR-19 north off of US-20, which is a much more direct route, but requires driving through the heart of Elkhart.  There was major road construction on this stretch of SR-19 the last couple of years, including a bridge, with narrow lanes and weight restrictions.  That work is all completed, and the road is much better now, but it is still a more urban route with stop lights, turns, and traffic.

Our coach (front, right) at the FMCA GLCC Surplus & Salvage Rally, Elkhart CG (Elkhart, IN).

Our coach (front, right) at the FMCA GLCC Surplus & Salvage Rally, Elkhart CG (Elkhart, IN).

I checked in to the campground and then got parked in my assigned site.  I was one of the last coaches to arrive.  I went through my arrival routine and got the coach setup to use before visiting with fellow GLCC chapter members, some of whom I had never met.  I chatted briefly with Michele Henry from Phoenix Paint to confirm her availability to work on a BCM article later in the evening and then went to Martins supermarket to get a salad for dinner.  The Martin’s supermarket on SR-19 at CR-4 has a really nice salad bar and I made a big salad with lots of ingredients, all vegan of course.

I took my salad over to the meeting room at 6 PM and had dinner with the group.  I was expecting Michele at 6:30 PM so I excused myself and went back to my coach.  She showed up a little after 7 PM.  We worked until almost 10 PM and managed to go through the entire article.  I did not have the photos on my new computer so the selection, processing, and captioning of images will occur later.

2014/10/09 (R) GLCC Surplus and Salvage

I went over for coffee around 8 AM without eating breakfast first.  By 9 AM plans had been made for car pools to visit the various RV surplus and salvage businesses in the area.  I went back to the coach and had a grapefruit for breakfast and then spent the morning taking care of e-mail and uploading blog posts starting with September 19th.

By noon I was tired of staring at my computer so I turned my attention to the speedometer.  After removing the dashboard cover I figured out a socket and ratchet combination that allowed me to remove the two Nylok nuts from the back of the instrument.  With the retaining bracket removed the old instrument slipped out the front of the dashboard.

Rear view of new VDO speedometer with custom adaptor cables.

Rear view of new VDO speedometer with custom adaptor cables.

I needed to redo the wiring so I got out my electrical tools.  I also tested to voltage to verify that the lighting circuit was 24VDC.  It was, and the actual instrument runs on either 12 or 24, so it didn’t care.  The existing connectors for the old instrument appeared to be the same 4-pin flat connectors used in personal computers for providing power to hard disk drives, CD drives, and other peripheral components.  I checked online and found that Michiana PC was located behind Menard’s a short distance away on the other side of the toll road.  I got an adapter cable with the proper connectors on it and then stopped at Menard’s for two different spade connectors.  As long as I was out driving around I stopped at Phoenix Paint to pick up coupons for Marco’s Pizza.  Since I had to drive past Martin’s on the way back to the campground I stopped and bought groceries.

The new VDO speedmeter temporarily connected.

The new VDO speedmeter temporarily connected.

Back at the coach I put the groceries away and got back to work on the speedometer project.  I cut leads from the old instrument light wiring as I needed the plug.  I then cut the unneeded end off the computer power cable.  I wired the lighting connector, spade connectors, and jumpers.  I then wired the instrument connector spade lugs to the computer power cable.  When all the wiring preparation was done I attached all of the wires except the two for the signal (#16 & #20) and connected the cables to mating chassis connectors.  I temporarily set the speedometer in dashboard hole, turn the chassis batteries on, and then turned the light switch on for the dashboard lights.  The speedometer lights worked, so I turned the ignition to ‘ON’ without starting the engine.  The gauge needle swept up to max and back to zero and the odo displayed 0.0.

I turned the ignition off and disconnected the chassis batteries.  I then pulled the instrument out of the dashboard and disconnected the two cables.  I got the H3-40 Service Manual out and figured out which wire was the + signal (#16) and which one was the ground (#20).  With the cables protruding through the mounting hole from the rear I pushed the spade terminals fully on and reconnected the cables.  It was getting to be late afternoon by this point and I decided to leave the finally assembly for tomorrow.

The new VDO speedometer (above & right of center).

The new VDO speedometer (above & right of center).

I took a shower and shaved and had plenty of hot water as the Aqua-Hot continued to cycle automatically.  I prepared an Annie’s Kung Pao noodle bowl for dinner and took it over to the meeting room at 6 PM.  I stayed there until 8 PM enjoying bus chat with a small group of chapter members that I know well.

The new VDO speedometer installed in the old hole.

The new VDO speedometer installed in the old hole.

Several members developed problems with their BCM subscriptions over the summer.  Pat Lintner gave me a flash drive so I could provide him with the issues he did not receive.  I took care of that back at the coach and then continued to upload blog posts and respond to e-mails.  I was two days behind on writing blog posts and stayed up until I was caught up which made for a very late night.

2014/10/10 (F) Bus Business

I was up way too late last night catching up on writing drafts of blog posts for the last few days.  Linda sent a text message this morning at 6 AM that I read at 7:30 AM letting me know that she was starting the drive to Elkhart.  I went over to the meeting room at 8 AM to have coffee and Linda showed up at 9 AM.  We visited with the other rally attendees until 10 AM and then went back to our coach to have granola for breakfast.

L-to-R:  GLCC secretary Tami Bruner, Newsletter editor Scott Bruner, and Treasurer Linda Fay.

L-to-R: GLCC secretary Tami Bruner, Newsletter editor Scott Bruner, and Treasurer Linda Fay.

At 10:30 AM we drove to Phoenix Paint to deliver some additional copies of Bus Conversion Magazine to Michele and visited with her and Roxanne for a while.  Josh was supposed to come look at our coach in the afternoon but had to make an unexpected trip to Chicago.  Michele called him and got him rescheduled for tomorrow morning between 9 AM and noon.

Before returning to the campground we stopped at Martin’s supermarket for salad toppings and Radio Shack for a miniature “grain of wheat” light bulb.  Radio Shack did not appear to have the bulb I was looking for, but I learned later in the day from Butch that the bulb I need comes with two bare wire leads that fold over to form the contacts.

GLCC members gathered for the Friday evening dinner and business meeting.

GLCC members gathered for the Friday evening dinner and business meeting.

When we got back to the coach we were going to have lunch but I got busy giving a tour of our bus tour and then touring the late 1990’s MCI 102D Vantare conversion parked next to us.  Butch and Fonda arrived (in their car) while all of that was going on.  We visited for a while and then they took off for Bontrager’s RV Surplus store.

Many of the GLCC members were away shopping for surplus bargains so we hung around our coach where I worked at my computer and Linda read until she got tired and laid down briefly.  I was thinking about lying down too when Pat Lintner stopped by and then Butch/Fonda returned.  Before we knew what had happened to the afternoon it was getting to be dinner time.  Linda made our dinner salads and we went over to the meeting room a little before 6 PM where we enjoyed our salads in the company of our friends.  President Larry Baker conducted a brief business meeting at the conclusion of which Linda was elected to another 2-year term as chapter Treasurer and I was elected to a 2-year term as chapter President.  Dean Chipman was elected chapter Vice-President and Tami Bruner was elected chapter Secretary.  Pat Lintner stayed on as National Director and Frank Griswold as Alternate National Director.

L-to-R: GLCC National Director Pat Lintner talks to newly elected President Bruce Fay and members Charles Martin and Ed Roelle.

L-to-R: GLCC National Director Pat Lintner talks to newly elected President Bruce Fay and members Charles Martin and Ed Roelle.

Butch and Fonda had to get back to their home to tend to their dogs and left shortly after the voting was concluded.  We visited for quite a while with the chapter members before returning to our coach for the evening where we had a glass of wine and went to bed.

2014/10/11 (S) Transfers

The day dawned clear and cold with the morning low temperature in Elkhart at 32 degrees F and frost on the ground and vehicles.  We went over for coffee at 8 AM and chatted with fellow chapter members while they had breakfast.  Josh was supposed to come look at our coach between 9AM and noon but called to see if late afternoon would be OK.  It was fine with me and he agreed to call before he came over.

We returned to our coach and had granola for breakfast.  We spent the morning chatting with folks, including the Thornton’s, who stopped by to pay their dues.  We had transferred some things to Linda’s car yesterday and transferred some more things this morning.  By noon Linda was packed and ready to leave for home.  She texted me later to let me know she had stopped in Ann Arbor to visit family and shop at Whole Foods Market before getting back to our house.

Ed Roelle and Marty Caverly came to our coach to listen to our Aqua-Hot.  Ed agreed that it should not be producing any visible exhaust after initial startup and thought a likely cause was worn bearings in the blower shaft causing reduced rpm which resulted in reduced air flow which resulted in a rich fuel/air mixture.  Ed and Marty both thought the unit sounded normal for a unit with worn bearings.

After looking at the Aqua-Hot I found former chapter President Larry Baker at his coach and we transferred quite a lot of “presidential stuff” to my car.  He had been collecting and transporting this “stuff” for the last six years and was all too eager to be rid of it.

Josh called at 3:45 PM to let me know he would be at my coach around 4:45 PM.  I made a quick run to Radio Shack to check again for the “grain of wheat” 12 VDC bulb, but they did not have it in stock.  Josh arrived a little before 5 PM and we discussed our desired interior renovation for over an hour during which time he also took measurements.  By the time we wrapped up our discussion most of the rally attendees had left for dinner at a local restaurant.  I called Linda and then had dinner in the coach; a simple green salad, a roll with garlic vegan butter spread, and grapes.

I decided to top off our fresh water tank while there was still some daylight rather than doing it in the morning when it was forecast to be cold.  After the tank was full I shut off the water, disconnected and drained the hoses, and stowed them in our fresh water tub.  I removed and stowed the pressure regulator and water softener.  I then turned each of the three Aqua-Hot loops on, one at a time, to see if I could figure out which circuit included the heat exchangers in the water bay and front storage bay.  As best I could determine, the bays are plumbed into the bedroom circuit.  I would have preferred to have them plumbed in with the bathroom as we like the bedroom cool for sleeping but want to be able to keep the bays warm enough to avoid freezing.

Scott Bruner and his dad, Richard, were out so I chatted with them about the Aqua-Hot.  The Marin’s had a propane camp fire going at their rig next to ours so we went over there to talk for a while.  I finally got cold and went in for the night around 9:45 PM.  I uploaded the blog posts for the last three days of September and then went to bed and worked on this one.

2014/10/12 (N) Arduino SBC

I got up around 7 AM, got dressed, and spent an hour packing clothes, computers, and other things that would eventually be transferred to the car for the trip home.  I went to the meeting room at 8 AM to have one cup of coffee and socialize with the GLCC chapter members who had come over for breakfast.  There are special names for breakfast on the last morning of a rally.  The one I like best is “hitch up breakfast.”  Whether you have a motorhome towing a car or a car/truck pulling a trailer, most RVers have something that has to be hitched up for towing before they can depart.  It is also a distant but quaint reference to hitching up a team of horses to a wagon; the original RV having one to six horsepower.

I do not normally have coffee or breakfast on days when I have to drive the bus, but the bus driving portion of my day was only going to be two hours and I would not be pulling out until sometime between 10 and 11 AM.  Those who wanted to eat breakfast were done by 9 AM and a crew of women busied themselves cleaning the kitchen and re-packing the supplies.  Some of those supplies were destined for my car which was already connected to the back of our bus, so everything got loaded into Pat and Vicky Lintner’s car and they brought it over to my site and I transferred it to my vehicle.

I dumped the waste water holding tanks and stowed the drain hose.  By 9:45 AM I was packed and had the bus and car ready to travel except for a few last minute details.  I joined a small group of guys for some final conversation as several coaches pulled out.  I was in a site directly behind Scott and Tami Bruner and although I could have left before them it was going to be a lot easier to wait until they pulled out, which they did shortly after 10 AM.

I went through the final steps of preparing the car to be towed, turned the coach chassis batteries on, turned the shore power off, disconnected the shore power line, and stowed it.  I had opened all the air valves earlier, so I secured all of the bay’s, locked the entrance door (from the inside), and started the engine.  While it was building air pressure for the suspension and brakes I called Linda at 10:29 AM to let her know I would be underway shortly and then called Butch.  I did not get an answer at Butch and Fonda’s house so I called Butch on his cell phone.  He had misunderstood my travel timing and indicated that they might not be home yet when I arrived at their place.

I pulled out of my site at 10:30 AM and reversed the route I had taken on Wednesday, going east on CR-4 (IN) to SR-16 (IN) north, to Old M-204 (MI) eastbound to US-12 (MI) east to M-217 (MI) south (the Michiana Parkway), which became CR-17 (IN) southbound.  I left CR-17 and got on westbound US-20 over to US-31 south which I stayed on all the way to SR-16 west towards Twelve Mile.  I had a call from Pat Lintner while I was driving regarding the dates for the 2015 Surplus and Salvage rally which will be in mid-September.

I arrived in Twelve Mile at 12:15 PM.  I got the car detached and moved it out of the way.  While I was doing that Fonda got home from church.  After tending to their two dogs (Rascal and Daffy) she helped me back the bus across the street into its parking spot next to their bus.  I plugged in the shore power cord to get AC power to the house systems but left the bus systems on temporarily so I could reprogram the new VDO speedometer.

On the drive from Elkhart the speedometer, which had not been calibrated, was indicating just under 8 MPH when I was traveling 60 MPH according to my GPS.  That meant the signal from the Allison ATEC transmission computer was putting out fewer pulses per mile than the default speedometer program.  For some reason I thought the default might be 200,000 PPM so I computed the ratio between actual and indicated speed and divided  200,000 by that number which gave me 26,316.  I programmed that in using the PULSE mode but would not be able to test it until later in the week.  If the indicated speed is in the ballpark I will use the ADJUST mode to manually move the pointer to indicate the same speed as the GPS.  There is also a CALIBRATE mode that counts the pulses over a one mile distance and then programs that into the instrument.  That is the most accurate way to calibrate the speedometer/odometer if you have someplace safe to do it with accurate mile markers.

With that done, I turned off the chassis batteries and the unneeded air circuits in the front bay but left the valve for the engine air accessories turned on.  I typically do this when I leave it with someone in case they have to start it.  I turned the Aqua-Hot electric heating element on and turned on the bedroom thermostat but set the temperature to a cooler setting.  The heat exchangers in the water bay and front storage bay appear to be tied-in with the bedroom heat exchanger.

I transferred stuff from the coach to car the car and by 1:25 PM I was ready to roll, but Butch called and said he was almost back to the house so I waited for him.  He had made progress on the Wiremold in the bus kitchen and wanted me to see it.  He had also bought a 125 A main lug electrical panel so we discussed the mounting and installation, part of which I will probably work on later this week.  He had also received the ITR Oasis Combi unit, so I had to see that too.  Fonda built a 3-D cardboard mockup and Butch had it sitting in the water bay where he plans to install the Combi.  We will probably do more work on their bus than on ours over the next two weeks, but that’s OK; their bus has more/critical projects at this point than ours and he has helped me a lot with our projects.

I pulled out at 2:05 PM and decided to take a slightly different route home:  SR-16 east, US-31 north, US-6 east, I-69 north, M-60 east, I-94 east, M-14 east, US-23 north, M-36 (Nine Mile Road) east, Pontiac Trail north, to Dorothy Street and the SLAARC monthly meeting at the South Lyon Witch’s Hat Depot.  I do not usually take US-6 across Indiana although it is a fine road known as the Grand Army of the Republic Highway.  It is flatter than US-20 with more towns and associated lower speed limits and stop lights, but it was a nice drive with different scenery.

I arrived at the SLAARC meeting at 7 PM.  The business meeting was already concluded and Mike (W8XH) was setting up for his program on the Arduino SBC (single board computer).  He bought the experimenters kit and had been playing with it enough to discuss it with the group.  Larry (K8UT) discussed the four projects he has built using the Raspberry Pi platform and passed around some of the hardware.

It was 9 PM by the time I finally got to our house.  Linda helped me completely unload the car as I had an 8:30 AM service appointment at Brighton Honda and she was leaving before 6 AM for the bakery.  She had fixed some strawberries for me and they made a nice treat after a long day of snacking on vegan junk food while driving.  I worked for a while on this post before turning in for the night.

2014/10/13 (M) Grain Of Wheat

Linda was up early and out the door at 5:45 AM.  I got up a little after 7 AM, started a load of laundry, had a couple of homemade muffins, and got ready to take my car to Brighton Honda for its 90,000 mile service.  I got coffee at the Dunkin Donuts across the street from the dealership first and waited in the lounge working on yesterday’s blog post while they worked on my car.

I forgot to specify synthetic oil so the put in regular oil.  When the car was done I headed to Novi and immediately noticed a front-end shimmy that was not there when I dropped it off.  They had rotated the tires and may not have re-torqued the lug nuts correctly.  It also pulled to left, which might be a tire inflation issue.  I did not have time to take it back so I will see if it settles out on the drive to Indiana tomorrow.  If not, I will need to get at least the front tires/wheels loosened and retightened, and perhaps balanced.  Worst case I will have to get the front end aligned.

I found the FedEx/Kinko’s on Grand River Avenue just east of Novi Road and made 10 copies each of two 24″x36″ electrical diagrams; one for the DDEC I ECM (Engine Control Module) and one for the Allison 700 Series ATEC (Automatic Transmission Electronic Control).  I folded up an ATEC diagram for me and one for Chuck and rolled up the other eight and put them in a tube for safe keeping.  Chuck and I have DDEC II’s controlling our main engines so I rolled the 10 DDEC I diagrams up and put them in a second tube to protect them.  By the time I was done it was 10:45 AM and Chuck was at his shop just up the street so I drove there.

He had installed a dual battery maintainer and wanted me to see it.  He mounted it on the back wall of the small bay above the passenger side drive tire of their bus which got it close enough to the chassis batteries (in a tray above the tag tire) for the built-in charging cables to reach the correct battery terminals.  He was still pondering where to tie in the AC power source so we discussed some alternatives.  He had also put the red covers on the bulbs in his new VDO speedometer so I got to see that.  Ours are white for now but most of the dash lighting is green.  The red makes the speedo stand out, but if I change ours from white it will likely be to green.  Chuck had a supply of spare 12VDC, 1.2W “grain of wheat” light bulbs that are used in our illuminated switches and let me have four.  Our Aqua-Hot switch does not currently light up when it is turned on.

After checking out his projects we went to the Panera at Grand River Avenue and Novi Road for lunch.  We had a good chat and solved all of the world’s problems so he went back to the shop to find some new ones and I went home to take care of chores.  I continued doing laundry and worked on the SLAARC WordPress website setting up user accounts for several new club members.

Linda got home around 5:30 PM and got busy making dinner.  She started with a nice salad featuring a ginger dressing.  Dinner was 45 minutes later; a baked potato with Brussels sprouts on the side, a glass of Leelanau Cellars Winter White with Peach wine, and grapes for dessert.  She worked on something for Butch while the potatoes baked and I worked on e-mail.

We were both tired after dinner but took some time to sort and fold the laundry from which I selected and packed the clothes I will need for the next 10 days.  We were tired and turned in after that.  I had received an e-mail from Butch with seven photos attached of the place we are considering staying in Quartzite, AZ.  It took us a while, but we eventually matched them up with the correct lot on the Google Maps satellite view.  It is not the corner lot as Butch and I previously thought, but the 3rd lot north of Kenoyer on the east side of N Lollipop Lane.  With that issue resolved we turned out the lights and went to sleep.

2014/10/14 (T) A Crowning Achievement

Linda was up at 5:15 AM again and out the door on the way to the bakery at 5:45 AM.  At this hour of the morning she has clear sailing all the way to Hamtramck which is much less stressful than the parking lot that develops on I-96 inbound just a short time later.  I was up at 7:15 AM, showered, and started gathering and organizing all of the stuff that I had to load into the car for the trip back to Indiana.

Keith showed up at 9 AM to cut the grass as I was loading my car.  He was rained out yesterday and today was not looking too good either but he figured he would have a go at it.  I wrote out his check and paid him in advance as I would be gone long before he finished.  I had time for a cup of green tea and pulled out of my driveway at 9:30 AM.

My first destination was Gusfa Dental in Dearborn, Michigan where I had an 11 AM appointment.  Dr. Steve and his assistant, Margaret, installed my new permanent ceramic crown on the upper right tooth that had a root canal procedure in mid-September.  The crown fit almost perfectly and only required a little modification on the surfaces that abut the two teeth immediately adjacent.  The bite was just right.  Gusfa Dental is definitely not the cheapest clinic around, but the work is top notch and they have been our dentists for almost 40 years.

I was done and out the door at 11:20 AM and headed directly for Twelve Mile, Indiana.  The drive was wet but uneventful.  Given my starting point in Dearborn I changed my route yet again, this time taking I-94 west to M-60 southwest to I-69 south to the I-80/90 Indiana Toll Road west to exit 92 at SR-19 (IN) in Elkhart.  From there I headed south on SR-19 and wound my way slowly through Elkhart until I picked up US-20 westbound on the south side of Elkhart.  From US-20 I picked up US-31 south and exited at IN-25 south of Rochester, Indiana where I bought some groceries at the Kroger store.  I texted Linda and then called Butch.  As I was getting ready to head south on IN-25 I got a call from Michele Henry of Phoenix Paint with some questions about the Zip Dee awnings we had installed on our coach after she finished painting it.  I took IN-25 as far south as Fulton and turned east onto a small farm road that took me to Meridian then south to SR-16 and east to Twelve Mile.

While driving down Meridian I saw one of the most intense and perfect rainbows I have ever experienced.  It was deeply colored, very clear, and an entire semicircle was visible.  A second rainbow, fainter and partial, formed above the first one on the right (south) end.  The sky was very dark to the east with bright, low sun from the west.  The trees were blazing with color, intensified by the rains, and white farm houses glistened as if they had just been freshly painted.  It was spectacular but I was not able to get a photo of it.  I arrived in Twelve Mile at 5 PM and immediately unloaded and stored my groceries.  I then brought my clothes and technology items into the house and put them in the guest bedroom where I stay when I am here.

Butch needed some parts for various bus projects so I drove us to Home Depot in Logansport.  One the drive in he got a call from his brother Tom.  He had a problem with his air compressor and wanted Butch to look at it so we went there after our stop at Home Depot, with a stop at the local Mobil station so I could fill the fuel tank in my car.  Butch quickly made a tentative diagnosis of the compressor problem as the starting capacitor and/or switch.  Tom and Butch did some pondering about details of Tom’s project in which he is converting the front half of a Crosley sedan into a trailer.

We visited for a while back at the house and looked up the grain of wheat bulb I needed for the illuminated switches in the H3-40.  Napa Auto Parts shows it in their automotive lighting catalog as a #37, 12 VDC, 1.26 W, wedge based.  Butch looked online and found a place (Bulbtown) that sells them for $0.42 each.  Orders over $50 get free shipping and handling so we discussed doing a bulb inventory of each bus and then pooling our orders.

I spent a few minutes showing Butch how the photos that Joe sent of the lot in Quartzite matched up with the Google Maps/Earth satellite and Streetview images.  By the time we were done with that it was late and we all turned in for the night.

2014/10/15 (W) MC-9 AC Wiring

Cockpit house systems switch panel.

Cockpit house systems switch panel.

Butch bought a brass nipple (NPT) last night to thread into the fitting on his fresh water tank but the fit was still too loose.  He needed the nipple in order to put the fresh water tank back in the bus.  Between that and the really soupy 54 degree F weather it was obvious that today was not going to be an outside work day.  I suggested that we work on the AC wiring on their bus instead—a nice inside project—after breakfast.

House electrical closet in Butch & Fonda's MC-9 before rewiring.

House electrical closet in Butch & Fonda’s MC-9 before rewiring.

I had homemade granola with fresh blueberries and soy milk, a glass of orange juice, and two cups of Seattle Blend 1/2 decaf coffee.  While the coffee was brewing I unscrewed the switch panel with the Aqua-Hot switch and replaced the “grain of wheat” bulbs in the Aqua-Hot switch and the Engine Preheat switch.  We then got to work on the AC (house) wiring for their bus conversion.

New 20-slot AC panel for inverter circuits.

New 20-slot AC panel for inverter circuits.

The bus had three small main lug load centers, with six circuit breakers each, mounted in a future closet in the bedroom.  We ran an extension cord through the passenger side rear slider window to power a work light, disconnected the shoreline, and switched off the inverter.  I then removed the three panels one at a time, labeling each cable as I pulled it out.  With all of the old panels out we mounted the new 20-position panel box for use with the inverter circuit.  I spent the rest of the work day, except for a lunch break, pulling old and new electrical cable into the new box and making the connections to the ground bar, neutral bus, and the GFCI circuit breakers for all of the circuits that will be fed by the inverter.  We tied in the main AC power to the inverter AC input and checked that all of the circuits worked as planned, which they did.  I will mount two of the smaller boxes tomorrow and pull the cables for the shorepower/generator only circuits into those boxes.

We quit working for the day at 7:30 PM and I washed up before making my dinner.  I had a nice salad with “power greens” and various toppings and leftover Koshary.  Yum.  I drew a glass of Moscato, did the dishes, and went back to the house.  I had a text and an e-mail from Linda so I replied to those.  We were all tired and turned in a little after 9 PM.

 

2014/10/01-07 Bus Work Plus

This post covers October 1 – 7, 2014

2014/10/01 (W) Aqua-Hot (Plus)

I woke up this morning sometime between 7:00 and 7:30 AM and worked for a while in the bedroom.  By 8:30 AM I heard voices, which meant Butch and Fonda were up and dressed, so I emerged from the guest bedroom to see what the plans were for the day.  I knew they would involve trying to fix our Aqua-Hot diesel-fired hydronic heating system, but I was not sure exactly how that work would proceed.

The first task, however, was to have breakfast.  Granola with fresh blueberries, red raspberries, and blackberries, plus orange/grapefruit juice and coffee.  Ahhh, coffee.  I did not get any yesterday, so I enjoyed having some this morning.

Butch & Fonda's Aqua-Hot in a bay of their MC-9.

Butch & Fonda’s Aqua-Hot in a bay of their MC-9.

Sometime between 9:30 and 10:00 AM Butch and I got to work on the Aqua-Hot situation.  We tried firing up my unit multiple times but it would not ignite and we had no evidence of fuel getting to the nozzle.  Butch added water to his unit and fired it up just to verify that it worked.  We unplugged the controllers from both units and connected my controller to his unit to see if the controller was the problem.  It wasn’t; his unit ran fine with either controller.  We put his controller on my unit, just to check, but the unit still would not ignite.

We decided that the most expedient course of action was to simply install his burner in my unit.  That was the point at which we realized that our units are not identical.  Ours is an AHU-103-000, originally made in the late 1980’s and early 990’s while theirs is an AHE-100-02s (?? check this).  The differences are minor but important, namely:

  • the fuel connections into and out of the burner are not the same so our fuel lines would not connect directly to their burner.
  • their burner had two fuel lines that ran down to bulkhead connectors while our unit did not use bulkhead connectors.

I had agreed to buy their entire Aqua-Hot to use for spare parts, so we started by removing the burner from our unit and setting it aside.  My plan is to repair it eventually or disassemble it for parts.  The problem is that I suspect the fuel pump and/or fuel valve and/or fuel valve solenoid are defective so I would have to determine whether that is the case.

Removing our burner was a bit more complicated that we thought it would be.  Besides the fuel lines, which had to disconnected and plugged, we had to disconnect a wiring harness that had four wires running into the main boiler box for the temperature control thermostat and over-temperature safety thermostat.  These wires were terminated in female spade connectors pushed on to the male spade lugs on the thermostats.  Rather than try to feed them through the small hole in the case I made a diagram of which color wire went where and then cut the connectors off allowing the wires to pull out easily.  We had to repeat this procedure on Butch’s burner.  Quite a bit of diesel fuel leaked out of various fuel lines and I kept soaking it up with paper towels.  With our burner out of the way we evaluated the situation and decided to take care of two other issues before proceeding with the Aqua-Hot.  That’s how it goes with bus projects.

The first issue was the check valve on the Parker FPM-50 Fuel Polishing Module installation, which had been leaking at the gasket between the two halves of the body since I had redone the fittings and reinstalled it.  I had a new (unused) check valve that I should have installed when I redid the fittings, but I didn’t.  The fuel line on the inflow side of the check valve was already loose so we disconnected the other end.  That allowed us to work in the shop with a vice to help hold parts.  We removed the fittings from the old check valve, cleaned them up, and assembled them to the new check valve using pipe thread compound rather than Teflon tape.  We then reassembled the new check valve assembly back into the FPM-50 system.  We turned the FPM-50 on and did not have any leaks; finally.

The second issue was related to the fresh (potable) water plumbing.  When we purchased the coach five years ago the fresh water system had two 12VDC water pumps plumbed in parallel with independent shutoff valves for the input and output sides of the pumps.  The system also had a surge tank.  Last spring (or fall?) I had replaced these two pumps with a single Shur-Flo 4048 model, removed the surge tank (which was not needed or recommended for the 4048), and used flexible hoses and various adapters to get the new pump connected in to the existing plumbing, including plugs to seal unused fittings.  That left a lot of plumbing in this part of the bay (just off the end of the Aqua-Hot) that did not perform any useful function and was in the way of other things, like the FPM-50.

All of the original plumbing in the coach is Quest, which is no longer made.  After studying the system for a while Butch realized that that Quest tubing at the valve on the end of the outlet hose had to be connected by being slipped over a barbed fitting and tightened with a swaged band.  If we could cut the band and get the fitting out of the tubing we could cut a different section of tubing, allowing us to remove all of the unnecessary plumbing, reinsert the barbed fitting into the cut line, and put a clamp on it to seal it.  Butch had a special tool for clamping bands on PEX tubing and it appeared that the bands were a compatible size for the Quest tubing.  He also had his tubing cutter handy, so we removed the band (which was copper and easily cut), and proceeded as just described.  The PEX band swaged down nicely and passed the “Go /No-Go” test (a special tool that gages the clamped band to ensure it is tight enough without being too tight).

We turned the water pump on and had a leak at the plastic double-ended male nipple between the end of the hose and the Quest fitting.  With the pump off Butch removed the hose and then the nipple.  It was cross-threaded but the threads were OK.  Both the hose and the fitting are sealed by rubber gaskets anyway, not by the threads, so I reassembled the three pieces snug but not over tight.  I turned the water pump on (up in the house portion of the coach) with Butch watching for leaks and we did not have any.  It was shaping up to be a very good day.

With those two issues resolved, and lots more room to work on my Aqua-Hot, we removed the bulkhead fittings from Butch’s unit and cleaned them up with a wire brush wheel in his shop.  Butch reassembled some of the parts in the shop with pipe thread compound and I installed them in two unused bulkhead holes in our unit.  I then threaded in the two final fittings on the outside of the unit and had Butch do the final tightening.  He is stronger than I am, and very experienced at working with this sort of technology, so he has a good feel for how tight things need to be and can make them to correct tightness.

It was finally time to install their burner in our unit.  I stripped the ends of the wires that go into the burner box, set the burner roughly in place, taped the wires to a piece of plastic banding, and fished the wire harness up into the boiler box.  Butch installed the new female spade connectors onto the wires while I was doing something else, but I do not recall what it was.  I installed the connectors onto the mating pieces on the temperature limit switches.  (Because of the way my Aqua-Hot is installed I have to work bent over at the waist.  This is very hard on Butch’s back, and by the end of the day my back was a bit sore and stiff as well.)

The burner assembly is held against the combustion chamber by two captive bolts that swing into position.  The bolts have flanged nuts on them that tighten down and hold the burner snug to the boiler.  Because our unit is installed “sideways” it is very difficult to see and reach the nut on the lower back side of the burner.  The nuts are 10mm (Webasto is a German company) and a ratchet with a 10″ extension is needed to reach them.  I found the best way to attach the burner was to hold it in position with my left hand, get the upper/outside bolt in position with my right hand, and then run the nut down with my right hand, but not too tight.  I continued to support the burner with my left hand while I reached over the top to find the other bolt by feel, flip it into position, and tighten the nut enough to keep it from slipping off.

I knew I had to be very careful with these bolts as over tightening them can crack the mounting flange on the combustion chamber; a big mistake.  I held the burner with my left hand and made sure it was fully and properly aligned with the combustion chamber flange and then alternately snugged the two nuts down.  The specifications on these nuts is for “20 to 40 inch-pounds.”  That is not a lot of torque.  Butch had a really good digital readout torque wrench, but it only went down to 60 in-lbs, so I had to guess.

With burner re-installed, Butch attached the two burner fuel lines to the appropriate bulkhead fittings.  These are flare connectors so they did not use pipe thread compound.  I then attached the supply and return fuel lines to the appropriate fittings on the outside of the bulkhead connectors.  These were barbed fittings that the rubber fuel lines slipped over and were secured with band clamps.

We turned the unit on (in the coach) but it did not fire.  One concern, which I will remedy tomorrow, was that the level of fuel in the tank might be close to the lower end of the pickup tube for the Aqua-Hot.  These tubes are usually installed so that accessory devices, like heaters and generators, cannot use the last 1/4 tank of fuel, ensuring that there is fuel available to start the main engine and travel a reasonable distance (to get more fuel).  It took three tries to get it to ignite and when it did it produced a lot of white smoke, which is unburned fuel.

While the unit was running Butch checked the exhaust leak and said it appeared to be under the coach, not up at the Aqua-Hot itself.  That was a lucky break and big relief.  The beginning of the exhaust pipe slips over a pipe thread nipple that is threaded into an elbow and is secured with an exhaust pipe clamp.  Butch saw telltale streaks of black soot indicating that exhaust gases were leaking out at this point.  We shut the unit off and let it cool down enough that I could remove the pipe clamp securing the exhaust pipe to the nipple.  Both bolts were very rusty, and did not come off easily, but I got them off.  Butch had one clamp of the correct size on-hand so I installed it.  I will get a second clamp tomorrow when we go to town, plus a replacement if a Butch wants one.

We turned the unit back on and again it did not want to ignite.  Butch though it was a fuel delivery problem, such as a loss of prime, or perhaps air was getting into the line.  After a couple of attempts I turned the Parker FPM-50 on and let it run for a while, thinking that it might re-prime the line.  I turned it off after 10 minutes and turned the Aqua-Hot on.  It went through a long pre-combustion purge stage and then finally ignited.  It produced copious amounts of white smoke initially, but after 10 minutes there were no visible exhaust fumes.  Butch is suspicious of the FPM-50, either the unit itself or the installation, but I have run the Aqua-Hot successfully many times subsequent to its installation until it failed to fire this summer.  Clearly the situation requires further investigation which will happen tomorrow or Friday, depending on the weather.

The unit heated up fully and shut off automatically after which I turned it off.  I then mounted my burner onto Butch’s combustion chamber, both to protect it and to make sure some small animal did not take up residence in the combustion chamber.  The only thing left to do on our Aqua-Hot was to mount the new Oasis expansion reservoir.  We determined that we could mount it to the side of the unit with short sheet metal screws.  I held it in place and marked the hole locations, center-punched them, and drilled the out using a bit that Butch gave me.  The housing is stainless steel and was difficult to drill even though it was thin.  I had 1/2″ screws and Butch found some washers.  It took some fiddling, but I finally got it attached through all eight holes.  We will switch the overflow tube from the undersized reservoir that came with the coach to the much larger Oasis reservoir tomorrow after the unit has cooled down overnight and drawn most (all) of the coolant back into the boiler.  I put the cover back on the burner end, we put our tools away, and called it a day.  And a good day it was.

Butch’s brother, Tom, and his wife, Tracey, came over during the late afternoon.  It was 7 PM by the time we were done working, so we got cleaned up (sort of) and drove down to the Old Mill Restaurant just west of town on SR-16.  I had a small pizza, no cheese, with onions and mushrooms.  They made the crust thinner than their usual and it baked up very nicely.  Once we got back to the house I worked on this post while Butch dealt with e-mail and Fonda worked on the wedding dress she is making for their daughter Jean, who is getting married just before Thanksgiving.  After we turned in for the night I off-loaded all of the photos I took of our day’s work and then went to sleep.

Our Aqua-Hot in a bay of our Prevost H3-40.

Our Aqua-Hot in a bay of our Prevost H3-40.

2014/10/02 (R) Aqua-Hot (Or Not)

I was up at 7:30 AM and fixed breakfast in the coach at 8; granola with fresh blueberries, red raspberries, blackberries, and almond milk.  A glass of orange/grapefruit juice, but no coffee.

Butch and I left at 9 AM to run errands in Logansport.  He stopped at a filling station that sold kerosene and bought four gallons.  I will explain why later.  I got a big cup of coffee there and it was a decent brew.  Our next stop was NAPA Auto Parts where I bought a 1.75 inch exhaust pipe (muffler) clamp and Butch picked up some things he had ordered.  Next stop; Rural King.  We do not have this chain anywhere near where we live.  It’s a kind of hardware, sporting, and home goods store that carries an interesting assortment of items that might be of use to farmers.  It’s not a fancy store, but it carries a lot of stuff and is well organized.  Butch needed some carpet tacks and I bought a fruit fly trap and an insect fogger.  Rural King also has free popcorn.  (Now you know the real reason we stop there.)  I got some on the way in and on the way out.  🙂  Our last stop was at Aldi’s where Butch picked up some things they needed for their dinner tonight.

When we got back to Twelve Mile I changed clothes and got to work.  The weather forecast was for rain and warm temperatures.  Rain had already wet the pavement around the buses so Butch gave me a large sheet of corrugated plastic to lie on while I installed the muffler clamp on the Aqua-Hot exhaust pipe.  I installed it next to the one I put on yesterday but pointing in the opposite direction.  These clamps are just “U” bolts with a matching saddle that completes the other half of a circle when slipped over the U-bolt and tightened with the nuts.

The Aqua-Hot had cooled off overnight and suctioned all of the coolant in the expansion reservoir back into the boiler.  That allowed me to disconnect the overflow tube from the bottom of the reservoir with a minimum of mess and attach it to the main fitting on the new Oasis tank.  I added a 50/50 mix of water and ethylene glycol antifreeze to the tank until the level was halfway between “minimum cold” and “maximum cold.”  This should have been the final Aqua-Hot task, but it would not ignite when turned on even though it worked yesterday after the burner swap.

I removed the service cover and Butch and I started to puzzle out what the problem might be.  When I turned the switch on at the dashboard the blower came on immediately but the fuel valve apparently did not open.  We don’t know if the spark igniter was working, but the burner never lit and eventually the blower shut off.  When that happens, the controller “locks out” the unit from even attempting to turn on again and I have to turn the switch off to clear the lockout and then turn it back on.

Butch had me disconnect the supply and return fuel lines on the outside of the bulkhead and replace them with clear fuel lines about 5 feet long so they would reach into the bottom of the kerosene container.  (Remember the kerosene Butch bought earlier?  Now you know what it was for.  He will eventually use it to fuel a heater.)  He thought we might have an air leak in the fuel lines/connections and the clear fuel lines would allow us to see the air bubbles.  By drawing kerosene out of the container, pumping it through the unit, and returning it to the container we could recirculate it indefinitely as long as none of it was being burned.  Even with combustion taking place most of the fuel gets returned as the unit only burns fuel at the rate of 1/4 gallon per hour.

With the kerosene setup we had taken the coach’s diesel fuel lines, including the Parker Fuel Polishing Module, completely out of the system.  Butch suspected the FPM-50 might be the culprit and thus did not except to see air bubbles, but we did; a lot of them.  And the unit still wasn’t firing.  We were perplexed and a bit frustrated.  On the other hand, it appeared that the FPM-50 was no the culprit, or at least not the only culprit.

Since his burner had always worked well in his unit we figured the problem had to be something in my unit.  Butch got the service manual for his unit, which is almost identical to mine, and we started looking at wiring diagrams.  The units have four thermostats; two for the diesel burner and two for the 120VAC electric heating element.   We thought those might be the problem and checked the two for the burner but they were OK and appeared to be functioning correctly.  There are also six fuses.  I pulled and checked each one and they were also OK.  When Butch works on his unit he often starts it by connecting a jumper wire across the two terminals for the switch wires to save himself the trip to the bus (where the switch is located) and back to the bay (where the unit is located).  He connected a jumper wire across the switch terminals on my unit and it fired up after the normal 25 second purge cycle.  It was good that it started, but not good that we did not know why.

We were still seeing a lot of air in the kerosene and Butch decided to remove the secondary fuel filter from its holder and change its orientation so the output was lower than the input, ensuring the outlet was covered by fuel.  The air bubbles lessened considerably when he did this but did not clear up completely and the unit was producing a lot of white smoke (unburned fuel).  It always produces some on startup until the combustion chamber heats up, so we decided to let it run.  The exhaust fumes eventually cleared up and the coolant eventually expanded to within 1.5 inches of the top of the (new) overflow reservoir when the unit reached maximum operating temperature, automatically shut off the burner, and completed the purge cycle.

We wanted to cool it down so we could test it again so I removed the jumper wire to keep it from restarting.  I then opened all of the coach windows, opened all three ceiling vents, turned the ceiling exhaust fans on high, turned the three Aqua-Hot house thermostats on, and turned them up to their highest temperature settings.  I also turned on the engine pre-heat coolant circulating pump.  As the unit cooled down it started drawing the coolant from the reservoir back into the unit.  We turned the unit on using the switch at the dashboard and it fired up.  At this point we had not found anything wrong and had not fixed anything, but it seemed to once again be working correctly.  While the unit was heating up and cooling down Butch repaired a flat tire on a semi-trailer that they used to store parts for their business.

I still had the fan coil heat exchangers and the engine pre-heat running to cool the unit down.  The power for these units, and for the coolant circulation pumps, is independent of the diesel burner as the Aqua-Hot can also be heated by an electric element and by the main engine.  When the unit had cooled sufficiently I removed the temporary fuel supply line and reattached the supply line from the diesel fuel system.  I left the clear fuel return line connected at the bulkhead.  I removed the heavy rubber fuel line from the bottom of the FPM-50 check valve, cut the clear line to a workable length, and attached it to the bottom of the check valve.  By leaving the section of clear line in place we would still be able to monitor for air bubbles.

After cleaning up diesel fuel that had leaked out of hoses and fittings I turned the burner on using the front switch.  The unit immediately came to life and the burner ignited the way it is supposed to.  We still had some air bubbles in the return line, but no worse than before until I moved the secondary fuel filter back into its normal horizontal position.  That created a lot of air bubbles so I moved it back so the outlet was lower than the inlet.  I am suspicious of this filter and/or the lines attached to it.  The unit was working and there was no point in bringing it up to full temperature so I shut it off and installed the service cowling.  It will be interesting to see if it ignites tomorrow morning when it is cold.

Butch and Fonda worked on uninstalling their Aqua-Hot while I unloaded most of the parts, supplies, and tools from my car and put them on a cart in their now mostly empty warehouse.  As I was finishing it started to rain lightly.  We quickly gathered up our tools, stowed our tool boxes, closed up our bus bays, and moved everything else into the garage.  I shut off the ceiling exhaust fans, closed the vents, and then closed all of the coach windows.  I shut off the three house thermostats and the engine pre-heat pump and then moved my car back to its usual parking spot.  By that point it was raining harder.

Today was Fonda’s birthday but they did not have any special meal plans.  Around 4:15 PM I decided to go fill the fuel tank on the coach.  Gallahan’s Truck Stop is only 10 miles from their house and an easy run there and back on SR-16 and US-31.  I arrived on Tuesday with only 3/8ths of a tank and I wanted to eliminate the main tank fuel level as a potential source of the no-fire problem.  I was going to need fuel anyway for the trip to Elkhart and back next week and any subsequent movement of the bus.  I texted Linda from the truck stop to let her know it was Fonda’s birthday and suggested that she call their house later.

Butch and Fonda had leftovers while I was out so I dined alone in the coach.  I had a large green salad, some pretzels with hummus, and a tofu hot dog.  Apple cider and reheated apple/pear crisp topped off the meal.  Yum.  I brought my dishes and cutlery in the house and washed them.

Linda called while I was eating so I did not get to talk to her.  Butch was very tired and turned in early so I chatted with Fonda for a while about their various family members, many of whom I have met over the years, and what they were up to before retiring to my room to check e-mail and work on this post.  Although not as productive as yesterday it was still a long and tiring one.  Actually the days when you don’t feel like you have accomplished anything definitive are the hardest.

2014/10/03 (F) The Other Bus

I got up at 7:30 AM, got dressed to work, and then spent a half hour doing some preliminary packing.  I had breakfast in the coach (granola with fresh berries) and was enjoying my first cup of coffee while cleaning up a few dishes when Butch knocked on the door.  He was curious if I had tried starting my Aqua-Hot.  I had not, so I turned on the switch for the diesel burner.  The blower came on right away and then the burner ignited after a short purge cycle of perhaps 15 seconds.  The combustion was clean on startup with no visible exhaust smoke.  I checked the expansion reservoir and the coolant level had dropped overnight to the “minimum cold” reference mark.  The unit was running well and I left it on to complete a full heating cycle.

When I arrived in Twelve Mile on Tuesday I noticed some small flies in the kitchen as I was setting up the interior.  We had not used the coach since mid-June and had left a couple of windows slightly open to keep it aired out and prevent it from getting too hot.  We did not turn the refrigerator off, which adds heat to the interior.  The windows have screens, but the little bugs could have gained access through any number of places.  I set up the fruit fly trap I bought yesterday to try and rid the coach of the little bugs.

I also bought a fogger yesterday that I had planned to use today just before leaving for home, but the directions said to only leave the fog for two hours and then ventilate the space.  There were also cautions about removing/protecting food and cooking/eating utensils and eliminating ignition sources, including the refrigerator.  The refrigerator (and freezer) are full of food so that was more trouble than I was prepared for today.  I put dryer sheets in the cabinets under both sinks (kitchen and bathroom) and in the bay by the Aqua-Hot.  We found several acorns inside the Aqua-Hot when I removed the service cowling on Wednesday and I have read that animals do not like these dryer sheets.  The sheets cannot do any harm so there was no down side to trying this.

Our major focus today was two interior projects in Butch and Fonda’s bus, a 1987 MCI MC-9 Crusader II NJT (New Jersey Transit).  Like most owner-converted buses, it started life as a seated coach in revenue service and got a lot of use over the years before being sold for a small fraction of its original cost.  In the case of their coach the New Jersey Transit Authority ordered a large number of these MC-9 model coaches with special modifications for use as commuter buses, as opposed to a city bus or a tour bus.  The MC-9 proved to be a reliable coach and used ones make an excellent but economical platform for a DIY conversion project.

They needed help installing a piece of “FRP” (Fiberglass Reinforced Plastic) on a section of wall.  They have used this material, in white and almond, for wall paneling and as a ceiling headliner.  The material comes in 4’x8′ panels and is flexible but durable.  It brightens the interior, as it reflects light, and is very easy to clean.  The piece had to be fitted, marked, and trimmed several times.  This project occupied Fonda for much of the day, Butch for some of the day, and me for a small part of the day.

Butch & Fonda's MC-9 conversion in the process of being wired.

Butch & Fonda’s MC-9 conversion in the process of being wired.

The other project was electrical wiring for switched kitchen outlets and the ceiling lights in the kitchen and living room.  I spent most of the day working on this.  Butch had finally decided that I know enough about electrical work that I can be entrusted with these tasks.  He is using Wiremold surface mount boxes and wire channels, which makes a lot of sense in a bus conversion where you cannot necessarily run wires through the walls of the bus.

Butch had previously installed Wiremold 2-gang base plates for electrical boxes to hold switches and outlets.  We routed electrical cable (10, 12, and 14 AWG wire, both NM cable and separate conductors) between base plates and the AC power distribution boxes.  I wired up outlets and switches and tied in lines and loads.

Larry “the scrap metal guy” showed up about noon so Butch had to use the forklift to load a pallet of old Crosley radiator cores into Larry’s truck.  After Larry left Butch used the forklift to remove their Aqua-Hot from their bus.  Fonda and I helped get it off the forklift into the back of my Honda Element after which we returned to our electrical and paneling work.

I quit working around 2:15 PM, changed out of my work clothes into something cleaner and more comfortable for driving, and washed up.  I finished packing and then loaded the car for the trip home.  I had planned to leave at 3:00 PM and pulled out of their parking area at 2:59 PM.  I did not have lunch and would not be having dinner until 8 PM, so 30 miles up the road I stopped at a BP/McDonald’s, topped off the fuel tank, and had some French fries.  The stop added 30 minutes to my ETA but it took the edge off of my hunger which made for a more comfortable drive.

On the drive home I suddenly had the vague feeling that I had not turned off the 12VDC fresh water pump in the bus.  I called Butch and had him check it.  As I suspected, it was on so he switched it off.  The only reason this was a concern was that a leak downstream of the pump would result in the (full) fresh water tank eventually being pumped dry (lots of water flowing somewhere) and the pump then continuing to run until it burned out or burned up (fire?).

A little farther down the road it occurred to me that leaving the Aqua-Hot turned on tomorrow, while Butch and Fonda were gone for most of the day, was probably also not the best idea I’ve had recently.  I stopped at the Travel America on M-60 at I-69 and called Butch again to ask him to turn the Aqua-Hot off in the morning right before they left.

On the drive home fall was definitely in the air and perhaps even an early touch of winter.  I drove through heavy, blinding rain with strong cross winds just northeast of Elkhart, Indiana and was in and out of rainy/windy conditions for most of the drive in Michigan.  I called Linda as I passed Charlotte, Michigan which was less than an hour from the house.  I got home at 8:10 PM and she had dinner waiting which was nice.  We had a green salad and an Amy’s Roasted Vegetable pizza.  After dinner I unloaded everything from the car except the few tools I had brought back with me, and the defective Aqua-Hot.  We were both tired after long days and turned in early.

2014/10/04 (S) Chores

It continued to rain overnight and into this morning and we awoke to temperatures in the upper 30’s (F).  We went to our ham radio club breakfast and lingered until 10:15; longer than usual.  When we left we headed to Country Squire in downtown Howell to pick up the hose and cover for the Broil King outdoor grill.  We stopped at the bank and then at Teeko’s for three pounds of fresh roasted coffee beans.  Our last stop was Meijer’s, just across the street from Teeko’s, to stock up on non-perishable food for me for the next week.  While we were there I got a phone call from Chuck and agreed to meet him at his bus garage at 1 PM.  By this time it was already 11:30 AM.  We unloaded groceries at home and had a quick lunch of hummus, chips, and grapes. I left at 12:30 PM and Linda settled in for the afternoon to work on her bakery project.

Chuck had re-installed his repaired tachometer and installed his new VDO speedometer and I wanted to see how the speedometer/odometer was wired and get the model number.  It was a VDO-437-152 85mm 85/130 (MPH/KPH).  Chuck had also purchased a dual multistage battery maintenance charger and we had a long chat about where to install it and how to wire it in.  While I was there Linda sent a text message asking me to pick up rolled oats so she could make another batch of granola.

I stopped at the Meijer’s in Wixom, topped off my fuel tank, and bought three bags of Bob’s Red Mill Thick Rolled Oats and two bottles of wine.  Back home I started doing the laundry and working on my computer off-loading photos from my camera.  Linda wrapped up her work and took a break to read before starting dinner.  I backed the car up to the garage and we unloaded the spare Aqua-Hot onto a wheeled platform.  The unit was very heavy, but we got it out and down safely.

For dinner, Linda made a nice green salad, cooked up a really yummy squash we had not tried before, and made seitan stroganoff served over basmati rice.  After dinner she read and played online word games with her friends and relatives while I edited blog posts at my computer.  I brought the laundry up and Linda helped get my clothes packed for tomorrow.  Butch called to let me know that they were back from their family reunion and the Aqua-hot started right up when he turned it on.  Cool (hot).

2014/10/05 (N) Indiana Bound

Linda helped me get partially packed yesterday and I stayed up later last night than I should have, so I slept in a little bit this morning, but the smell of coffee brewing and breakfast cooking got me out of bed.  Linda made a tofu scramble with onions, mushrooms, and green peppers and served it with toast and coffee.  That was a nice way to start the day.

After breakfast I checked e-mail and then started gathering up the remaining items I needed to take with me to Indiana.  I had more clothes than the last trip since I would be gone seven nights rather than three and I would be involved in working on buses initially and then attending a rally.  This time of year the clothing needed to work outdoors can also vary considerably from day to day and even during the course of a day.

By 11:30 AM I was ready to load everything into the car.  Bags of food went on the floor in front of the passenger seat, my computer and carry bag went on the passenger seat, and the suitcases and bag of shoes and coats went behind the front seats.  I then backed the car up to the garage and loaded the items we hoped to get rid of at the FMCA Great Lakes Converted Coaches (GLCC) Surplus and Salvage Rally later in the week.

With the car packed, Linda reheated the seitan stroganoff from last night for lunch.  Even left over it was delicious.  By the time we finished eating and cleaning up it was 1:15 PM.  There wasn’t anything left to do at home, and Linda was waiting for me to leave before she got to work on the bakery software conversion project, so a farewell-until-later kiss sent me on my way.  I pulled out of the driveway at 1:24 PM.

The weather looked and felt more like early winter than early fall with moderately strong coldish winds moving an endless layer of mottled gray clouds from west to east.  It was neither gloomy nor foreboding but had that wintery edge to it.  I thought about alternate routes out of town but decided to take Hacker Road to M-59 the same way I do in the bus.  Most of my route was the usual; M-59 west to I-96 west to I-69 south to M-60 where I stopped at a McDonalds to rest and get a cup of coffee.  I then took M-60 west through Three Rivers to M-40 where I made a rest stop and topped off the gas tank at the Shell station.  Regular was $3.19, a price I have not seen in quite some time.  I took M-40 south seven miles to US-12 and headed west to M-217 (the Michiana Parkway) which runs south into Indiana where it becomes CR-17.  Instead of continuing on to US-20, however, I took CR-4 west to Elkhart Campground.

I stopped at the campground to make a reservation for Wednesday through Sunday (for the rally) but found out that I did not need one.  I confirmed the availability of 50A electrical service while I was there, took the opportunity for a pit stop, texted a trip update to Linda, and then continued my trip to Twelve Mile, Indiana.  Since I was in Elkhart and had a good phone signal I called Michele Henry of Phoenix Paint to remind her that I would be in Elkhart later in the week and that we had talked about getting together to review and finalize an article I had written some time ago on the process of renovating the exterior of our coach.

I took SR-19 south through Elkhart to US-20 west to US-31 south. The conversation with Michele lasted about three quarters of the way to Twelve Mile where I finally reached an area with no Verizon cell phone service.  (I find it odd that there is any stretch of US-31 without Verizon service as it is the major connection between Indianapolis and South Bend.)  I exited at Rochester onto SR-25 south and took that as far as Fulton where I took a couple of small county (farm) roads down to SR-16 at a point slightly west of Twelve Mile and drove east into town.  The trip took almost five hours, including the two stops, and covered 245.7 miles.

I had a marginal cell phone signal so I sent a text message to Linda letting her know I had arrived and asked her to call my hosts’ phone around 7:30 PM.  I said “Hi” to Butch and Fonda and then excused myself while I unloaded the car.  I unpacked the suitcase and stored most of the clothing in the bus, taking enough items into the house for the next couple of days.  I also unpacked and stored all of the food in the bus pantry.  I put my technology, toiletries, shoes, and work jackets in the house and then went back to the coach to have a quick bite of dinner.

I made my final trip for the night from the coach to the house just before 7:30 PM but managed to be in the house when Linda called.  She chatted briefly with Butch about some business related forms and then chatted briefly with me.  She will be working at the bakery most of the week, but plans to drive to Elkhart on Friday morning to visit with GLCC chapter members, have dinner, and participate in the business meeting.  She’s the chapter Treasurer.  She will stay the night, and through breakfast and lunch on Saturday and then head back to the house.  We can only leave the cats alone for so long.

Butch was working at his computer but cleared a chair off for me.  He had his 2m ham rig dialed in to the Miami County Amateur Radio Club repeater and they started their weekly net at 8 PM.  We had a long chat before I retired for the evening around 9:45 PM.

The plan for tomorrow is to continue working on the kitchen and ceiling light wiring in their bus.  I also have a few more places to look for the diagrams and installation notes for the Zena 24 VDC engine-driven power generating system.  Butch has an appointment on Tuesday morning and will pick up some things while he is in town.  I need a fuel line coupler (double barbed male) so I can remove the fuel lines from the final/secondary fuel filter on my Aqua-Hot, connect them together, and see if that eliminates the air bubbles.  He also needs parts for the rigid links he is making for the leveling valves for the bus chassis air-suspension system.  He is going to get extra material and make a set for me too.  It should be an interesting and varied week.

2014/10/06 (M) No Fuel Flow

Getting our Aqua-Hot to work is proving to be quite a challenge.  When Butch and Fonda got home early Saturday evening Butch turned on the burner and it fired up perfectly within the normal startup cycle time limits.  He left it on and I assumed it was working correctly when I arrived yesterday.  It wasn’t until this morning that I realized I did not have hot water.  The switch was on but when I checked the expansion reservoir it was below the minimum cold level.  The unit had obviously cycled off and then failed to restart sometime later.  Once that happened the control circuitry locked out the fuel and ignition spark as a safety measure.  I tried cycling it four times but it would not ignite.

Butch found a small inline (secondary) fuel filter and I replaced the one in the unit.  It still would not start.  I disconnected the fuel line from the outlet of the Racor fuel filter (which feeds to Parker FPM-50), disconnected the fuel line from the outlet of the FPM-50 (which supplies the burner), and connected the supply line directly to the Racor filter.  It still would not start.  Based on what we could see in the transparent secondary fuel filter the unit was not getting fuel.  There are a limited number of things that could be wrong: no fuel; bad fuel; clogged/restricted fuel line(s); clogged/restricted fuel filters; weak/broken fuel pump; stuck fuel valve or defective fuel valve solenoid; clogged nozzle.  We started the generator, which may use the same main tank pickup tube as the Aqua-Hot, and it ran beautifully.  I turned the electric toe-kick heaters on to put some load on the genset and let it run for a while.

Our next step was to change the Racor fuel filter / water separator and/or by-pass it, but it started to rain.  The forecast was for rain throughout the morning turning to thunderstorms in the afternoon with temperatures in the upper 50’s.  I did not want to work in those conditions so I put away my tools, closed up the coach, and spent the rest of the day (except for a quick lunch break) working on the 120 VAC wiring in Butch and Fonda’s coach.  I hope we have power to their new switched kitchen outlets and ceiling mounted fluorescent lights by the end of the day tomorrow.

I had leftover Ghallaba for dinner.  It was delicious.

Butch ordered a VDO-437-152 electronic speedometer/odometer for me from PartDeal.com which is part of ISS Pro (Instrument Sales and Service) with overnight shipping.  He then called Joe and got the address of the place in Quartzite, Arizona where we are thinking about spending part of the winter.  He and I spent some time checking it out on Google Maps, Google Earth, and Google Street View before turning in for the night.  I spent some more time checking out Quartzite and distances to the nearest towns with decent shopping.  I dealt with several e-mails, worked on yesterday’s blog post, and finally turned out the lights.

2014/10/07 (T) Loose Connectors

I was up much too late last night and stayed in bed this morning until just after 8 AM to make sure I got my 7 hours of beauty rest.  I was up and dressed by 8:40 AM, just in time to converse briefly with Butch before he took off for a shopping run and an appointment in Logansport.  Our plan was to attack the Aqua-Hot fuel flow problem when he got back, weather permitting.

After Butch left for town I had my usual bowl of yummy homemade granola for breakfast.  Rather than make coffee, however, I went across the street to the Small Town Brew coffee & bake shop that Lisa Paul opened a little over two years ago.  Lisa wasn’t there, but her friend Ashley was covering for her.  Coffee is on a donation basis and the only small bill I had was a $1, so I got a large mug of coffee, with a refill, for a buck.  Ashley was engaged in a conversation with a local farmer when I arrived.  She was very friendly, and included me as much as she could, but they were discussing local issues (of course) which involved family relationships and property sales, none of which meant anything to me.

I found out that Ashley’s boyfriend, Jeff, is slowly trying to buy up the whole town of Twelve Mile and turn it into a rental community.  Ashley helps Jeff renovate each property to make it rentable.  What they are doing probably makes some economic sense but long-term will destroy any sense of community that may exist in this place.  Renters simply do not have the same stake in a community as owners.  The town is very small with very little employment but is only 12 miles from three much larger towns (Logansport, Peru, and Rochester) and only 30 miles from Plymouth (north) and Kokomo (south), so it is possible to live here and drive to employment elsewhere.

Although Twelve Mile has a bank and a post office it seems like the sort of place younger and middle aged folks might rent for a while rather than someplace to settle for the long term.  I am, of course, looking at this through the eyes of a lifelong urbanite.  Butch and Fonda have lived here for a very long time and it has certainly met their needs for a place to live and run their business, as well as build/store their bus conversions.

I finished my coffee and returned to our bus to see if I could remove the defective speedometer.  The dashboard cover just lifts off, providing access to everything on the back side.  Not good access, as the dashboard is fairly close to the windshield, but access nonetheless.  I can also see the back side of the dashboard clearly through the windshield, so a second person can help direct tools into position if needed.

The old speedometer is held in with a U-shaped bracket secured with two Nylok nuts on machine screws that are part of the case.  The machine screws protruded far enough beyond the nuts to require a deep socket or a socket with a large enough through hole to allow the screws to pass through.  In order to get the socket onto the nuts I had to hold wiring cables out of the way.  I traced the wires coming out the back of the speedometer and discovered that the instrument connector was disconnected from the mating piece in the wiring harness.  The connector for the instrument lights was also unplugged.  Whatever the condition of the instrument it was guaranteed not to work in this configuration.

I do not recall how this situation came to be.  I was working on the dashboard wiring this past March while we were in Williston and presumably cleaned these contacts as the intermittent speedometer was the primary thing we were trying to fix.  Presumably I either failed to plug these connectors back together or did not plug them together fully and they eventually worked loose.  Having the connectors touching loosely could certainly have caused the intermittent and erratic readings I was seeing.  I decided to leave the speedometer in the dash, reconnect it, and see what it did on the drive to Elkhart.  I will have to decide whether to install the new speedometer when it arrives or keep it as a spare.  Either way I will need to test drive the bus.  Whatever I decide I do not plan to return the new one since it is the correct replacement part (per Prevost) for a speedometer that may eventually fail if it hasn’t already.

While Butch was away I worked at my computer selecting and editing photos for a few of the late September blog entries that I have not yet posted.  I should have some free time at the upcoming FMCA GLCC Surplus and Salvage Rally to get the blog and website caught up and also get some writing/editing done on articles for Bus Conversion Magazine.

With regards to my Aqua-Hot, Butch’s plan was to install short fuel lines on the inlet and outlet sides of my Racor fuel filter / water separator, insert T-fittings, reconnect the normal fuel lines to the T-fittings, and attach vacuum gauges to the T-fittings.  This configuration would allow us to monitor the relative pressure in the fuel lines on either side of the Racor to see if there was a restriction.  I have a replacement filter cartridge for the Racor but we did not want to install it unnecessarily.  It would have been easier but provided us with less information.

Although there are several components inside the Aqua-Hot that could restrict or prevent fuel flow, all of those came from Butch’s unit and were known good components before we swapped them over.  We also had the unit in our coach operating as recently as this past Saturday.  At this point all indications are that the no-start problem is fuel supply related and external to the unit, i.e., in our coach.  Ugh.

My new VDO speedometer arrived while Butch was gone.  I could not find Fonda so I signed for it.  I was eating lunch when Butch got back.  He bought barbed brass couplings for 1/4″ fuel line and 11′ of fuel line.  He did not buy T-fittings because he had a quantity on hand.  Unfortunately we could not find them so I made a quick run to Logansport to get the missing pieces.

Pressure gauges and T-fittings for testing the Aqua-Hot fuel delivery.

Pressure gauges and T-fittings for testing the Aqua-Hot fuel delivery.

When I got back I hookup up the two vacuum gauges as previously described and initiated a start cycle on the Aqua-Hot.  We did not see an indication of a restriction but the unit still would not fire. On two prior occasions we had gotten it to ignite by using a jumper wire across the two terminals where the cockpit switch wires connect.  We tried that again and it lit up. It was producing a lot of black exhaust so I let it run long enough to clear up.

The jumper wire may be a coincidence but I developed a hypothesis that we could test.  If the initial switch closure provided a sufficient voltage and current to start the operating cycle but then dropped below some lower threshold the controller would never open the fuel valve or apply power to the ignition coil for spark and the blower would complete the shutdown purge stage of the operating cycle.  I recall a quote from Thomas Huxley:  “The great tragedy of science – the slaying of a beautiful hypothesis by an ugly fact.”  With the cockpit switch closed (on) Butch measured 12.7 VDC across the terminals without any noticeable drop.  Even so, we investigated the switch and it’s wiring to see if the contacts might be intermittent.  They were not.  We did discover that the small “grain of wheat” light bulb in the switch was not coming on even though the filament appeared to be intact and there was voltage on the wire pair from the Aqua-Hot that powers it.

One of the house systems switch panels.  The Aqua-Hot burner switch is one of these.

One of the house systems switch panels. The Aqua-Hot burner switch is one of these.

We cycled the unit on and off several times and it ignited every time.  I removed the vacuum gauges and T-fittings, spliced the supply hose back together on the inlet of the Racor fuel filter /water separator, reconnected the outlet to the inlet of the Parker FPM-50, and installed a new piece of 1/4″ fuel line from the outlet of the FPM-50 to the inlet of the secondary fuel filter.  I checked all of the band clamps, turned the unit on, and it started right up.

I did a little more interior electrical work on Butch and Fonda’s coach, helped them install an FRP panel, and called it a day.  Since I was leaving tomorrow I did some preliminary packing of stuff in the bedroom.  I made and ate my dinner in the coach and then did some straightening up before returning to the house and turning in for the night.

 

2014/09/30 (T) To Indiana

Linda was up early again and off to the bakery.  I got up just before 8 AM, showered and shaved and had a grapefruit for breakfast.  I did not have any coffee.  I do not eat or drink on lot on days when I have to drive the bus.  I checked and adjusted the tire pressures on the bus while it was still cool and cloudy.  I then hooked up the car and checked the rear lights.  I spent the rest of the morning gathering up last minute things and loading them on the bus.  My plan was to leave at noon.  There were a lot of last minute things but I was packed and ready to go by 11:45 AM.

I called Linda to let her know I was getting ready to leave, secured the house, and took care of the final departure items.  I started the car, put it in D (drive) for 20 seconds, slipped it into neutral, made sure the parking brake was off, the steering wheel was free to turn, and the Pressure Pro repeater was plugged in.  The key has to be in the ignition switch and turned to the “on” position while the car is being towed so I travel with two car keys so I can lock the car.  I turned off the shore power to the bus, disconnected the power cord, and stowed it.  I closed up the utility (shore connections) bay, checked that the air accessories circuits were open in the DS front bay, checked that the inverter was working, and made a final check that all of the bays were closed and locked.

I secured the entrance door (from the inside), checked that everything was ready for travel on the interior, buckled myself in, and started the engine.  I gave it a minute to get oil flowing through the engine and start to build air pressure and then switched it to high idle to finish airing up the suspension and brake systems.  I switched the suspension system from Level Low mode to driving mode, pulled the tag axles up, let the suspension come back up to ride height, and slowly pulled out.  (Lifting the tag tires off the ground helps the bus make slow tight turns like the 180 degree turn to pull out of our pull-through driveway and into the street pointed in the right direction to get out to the main road.)  I stopped in the street to lower the tag axles, let the suspension readjust to ride height, and was finally on my way.  (The bus is not supposed to be moving when the tag axles are raised or lowered.)  The dashboard clock turned 12:00 when I was half way down our street.  That’s the departure drill.  The morning turned out to be busier than I would have liked, but that was pretty good time management, I would say.

It had rained hard around midnight and there was a heavy cloud layer all morning with occasional mist, so it was a cool, damp morning.  I took my usual route north on Hacker Road to M-59 west to I-96 west to the southwest corner of Lansing where I picked up I-69 south.  I stayed on I-69 into Indiana where I picked up US-20 west.  I always enjoy the drive across this stretch of US-20; it’s a 2-lane highway posted at 55 MPH (except through towns) and is hilly from I-69 west to the Elkhart area.  It is not unusual to see Amish buggies along this route but they were out in force today from Lagrange to Middlebury.  There was also road construction along the way so it was a slightly trickier and slower drive than normal.

I exited US-20 onto US-31 southbound and was immediately routed onto a new section of highway.  I have seen stretches of this highway under construction on trips to Twelve Mile Indiana over the last couple of years but this was the first time I had driven on it.  The road I used to take is now “Old US-31.”  The new highway rejoined the old highway near Plymouth, Indiana.  From this point south to Kokomo US-31 has long been a four lane divided highway, but not limited access.  At the point of rejoining one side was closed with traffic routed on the other side, making a 2-lane construction zone.  In spite of that I was able to keep rolling and made good time.  I was out of the construction quickly enough.

Once the highway made the turn back to the south near Rochester I was in the home stretch.  Another 10 miles and I saw the familiar communications towers that tell me to look for the barn on the east side of the highway at SR-16.  I made the turn onto SR-16 westbound and another 7 miles brought me to the heart of downtown Twelve Mile, Indiana where Butch and Fonda’s home and business are located.  (Twelve Mile, Indiana is 12 miles from Rochester, 12 Miles from Logansport, and 12 miles from Peru, thus the name.)  I pulled into the driveway for the grain elevator across the street from their parking area, let the engine idle for a few minutes to cool down and stabilize, and shut it down while I unhooked and parked the car.

Butch and Fonda had gotten home from a day of errands and family visits just before I arrived.  They unloaded groceries while I attended to my car.  Butch then served as spotter while I backed across SR-16 into their lot and got me parked next to their bus.  As parked, the coach was level side-to-side but low in the front.  I switched the suspension to Level Low, raised the front end, and shut off the engine.

I use their spare bedroom when I am here, so I unloaded clothing and technology items and took them inside.  I left all of my food onboard the bus, however, as I prepare my own (vegan) meals and usually eat breakfast and lunch in the coach by myself (if I even have lunch).  I try to prepare dinner and bring it in the house to eat with them if the timing works out, but tonight it did not.  They had a large, late lunch and I had a small, light breakfast and a handful of pretzel nibblers and peanuts (literally) for lunch.  Linda sent a lot of food with me for such a short trip, so I had a green salad and a hummus sandwich for dinner after which I settled in to visit for the evening.  My iPad remembered how to connect to their Wi-Fi and I got my ASUS laptop connected as well.  This is the first time the laptop has been to there place and only the second time it’s been out of the house since I bought it.

It was a bit strange seeing the place somewhat emptied out although there is still a lot of stuff there.  I was surprised at what the company in Nevada did not take, but Butch and Fonda both explained that the buyer had taken the stuff they were most likely to sell, had space to store, and could afford to ship 2,000 miles to Nevada.  Some remaining items with unique value may be sold but much of the remaining inventory will be sold as scrap.  Things are a bit chaotic at the moment as they had to move a lot of stuff to get to other stuff and are now going through their stuff trying to figure out what stuff to get rid of and how to get rid of it.  They are working towards being full-timers, so they have a big task ahead of them.

 

2014/07/14 (M) Education

Linda was up at 6 AM and was out the door and on her way to Twelve Mile, Indiana at 6:30 AM.  She decided last night not to have breakfast at home in favor of getting on the road.  I slept in and got up at 7:30 AM.  Lind’s homemade granola made for an easy, tasty breakfast.

Two landscapers showed up a little before 9:00 AM as I was getting ready to leave to run some errands and said Steve was on his way, so I stuck around until he got there.  We looked at a few things together and then I left.

On the way home from running my errands I got a call from TOMTEK reminding me that we have an annual service contract with them for the main house furnace (hot-water base-board heat) and air-conditioner.  I agreed to have them come on Thursday to service the A-C.  Perhaps while they are here they can figure out why it makes a noise that sounds like the thump, thump, thump of a helicopter blade.

About a mile from the house I spotted a small Painted Turtle trying to cross Hacker Rd.  A truck going the other way spotted it at the same time.  We both turned around and came back.  I got there first and put it on the front passenger floor mat after assuring the other driver that I was going to take it to our property and release it near the (neighbor’s) pond.  Turtles have very little chance of successfully crossing a road most places, including around here.

The two landscapers worked into the afternoon.  They could only go so far before needing Steve to inspect and approve their work.  He did not make it back today and I think they quit working around 3 PM.

Education is what I did professionally for the last 21 years before I retired, and I am still doing it to some small extent.  Back in the late winter I agreed to serve on a newly reconstituted FMCA national education committee.  There are 6 – 10 people on the committee, depending on how you count, and except for a couple of staff at FMCA headquarters in Cincinnati, Ohio we are spread out all over the U. S.  Our meetings are, therefore, conducted by telephone conference with ideas and information shared via e-mail in-between.  I also set up a folder in our personal Dropbox as a place to put documents so the committee can retrieve them.

We had our third meeting today from 4:00 to 5:30 PM EDT.  I spent the rest of the evening creating an outline of a possible RV curriculum and dealing with e-mail related to our meeting.  Linda got home at 8:00 PM and we had leftovers for dinner, after which I returned to my work and she headed to bed.

I have one, maybe two, days to concentrate on desk tasks.  Once the Pack-Rat storage container arrives on Wednesday I will be tied up with house-related chores through the 19th and then company through the 23rd.  I expect delivery of some HVAC equipment and materials during that window.  With any luck Darryll will be here starting on the 24th and I will be tied up working with him through the end of the month.  I’m hopeful, if not optimistic, that the landscapers will also be done with their two projects by the end of the month.

 

2013_09_17 (Tue) To Goshen We Go

We awoke this morning to temperatures in the mid 40’s.  As we had no reason to rush we stayed under the covers a bit longer than usual.  Lazy mornings are always a source of consternation for our cats who, in spite of the obvious presence of food in their bowls, expect us to get up at the first sign we are awake and attend to their perceived need for fresh(er) food.

I turned on the electric toe-kick heater in the bathroom to take the chill out of the air, but then decided to fire up the Aqua-Hot instead to warm up the entire coach and preheat the main engine.  At a seminar in Gillette, Wyoming this past summer we learned that the Aqua-Hot needs to run with some regularity in order to run well, so this was an opportunity to do that and to check my work from yesterday for leaks.  The Aqua-Hot ran quite well, but as I feared there was a small leak at the gasket between the two halves of the check valve.  I will try one more time to get a couple of wrenches on this part and tighten it, but if that is not successful I will have to install the new check valve, which would take another entire day.  Ugh.  I like doing projects, but I don’t care so much for doing them more than once.

We had oatmeal for breakfast, which is always nice on a chilly morning and has a certain staying power for days when lunch is uncertain.  After breakfast we got our coach ready for travel while Butch and Fonda did the same with theirs’.  We departed Twelve Mile, Indiana a little before noon with Butch and Fonda in the lead and headed for Goshen, Indiana to attend the Great Lakes Area Motorcoach Association (GLAMA) 2013 area rally (GLAMARAMA13).

Our route was IN-16 (Co Rd 700 N) westbound to N Co Rd 600 E northbound to IN-25 northbound to US-31 northbound to US-6 eastbound to IN-15 where we stopped for a stretch break.  We moved into the lead and continued northbound on IN-15 to Goshen with Linda navigating based on directions provided by the rally organizers.  We had been advised by FMCA to follow the directions they provided in order to avoid a bridge that was out on the main road to the fairgrounds from the west.

We tend to travel on Intestate and US highways, but have also found State highways to generally be good for travel.  Even county roads are OK if we know in advance we will not encounter weight, height, or width restrictions.  This is where it is helpful to have local information from folks familiar with the roads.  It also helps that our Rand-McNally RVND7710 GPS is configured to know the parameters of our rig, so we are able to travel with some confidence that we will not encounter unexpected obstructions.  As an added feature it also provides real-time traffic information, especially near larger metropolitan areas.

The trip up IN-15 brought us quickly into the outskirts of Goshen with heavy, slow traffic.  This presented a challenge for us as the buses do not accelerate that quickly and the lights do not stay green for that long.  It was important that I not lose Butch at a light as Linda had the detailed directions for getting to the fairgrounds.  As we came to downtown Goshen there was construction with lanes closed and traffic rerouted through barrel lined jiggy-jogs.  We pressed ahead none-the-less as we needed to go east on IN-4, just three short blocks beyond the construction.  We made it through but it was the kind of situation that adds a bit of stress to the usual pleasure of driving the coach.

We continued east on IN-4 looking for Co Rd 29 southbound.  Along the way we spotted an official looking sign that said “RV Rally and Fairgrounds” with an arrow pointing down a nicely paved road to the south.  I slowed down and considered taking this road—even though the turn looked a bit tight—until I noticed the “NO TRUCKS” sign on the adjacent pole.  We are never sure whether or not we are a “truck” so we generally decide one way of the other depending on what is to our advantage.  In this case I took a “pass” and continued on down IN-4 to CR-29.  We headed south on CR-29 until it ended at CR-34 where we turned westbound back towards the fairgrounds.  Our directions said to enter at Gate 3, but as we approached the northeast corner of the fairgrounds an orange-vested parking crew member motioned us to turn in.  I hesitated again, but decided to follow his directions.  The parking procedures are usually well thought out and the crews usually know what they are doing.  The whole arrival/parking experience generally goes much more smoothly if you simply follow their directions.

(It is worth noting, however, that as with a boat or airplane the driver of an RV bears the ultimate responsibility for it’s operation and is the ultimate decision authority with respect to that operation.  If the driver is unclear or uncomfortable with what parking crew are asking them to do, the correct response is to STOP, ask for clarification, and not move until they are certain they understand where they supposed to go and are comfortable (willing and able) going there.  Arguing with parking crew, however, is counterproductive, and ignoring them and moving the RV is potentially dangerous.  Parking crew are there to move large numbers of RVs efficiently and safely to planned parking areas and drivers should always give them their full cooperation but never surrender their ultimate decision authority.)

We arrived at the rally venue a little before 2 PM.  The usual procedure is to unhook a towed vehicle and drive it, separate from the motorhome, to the site or a designated parking area.  And so it was today.  They had changed the entrance gate to channel us into an area where there was more room to unhook our towed vehicles.  With the cars unhooked, we proceeded to the holding area where we queued up and waited to be escorted to our site.  For this rally parking areas had been reserved for chapters so they could park together without having to arrive together (caravaan style).  We were part of the reservation for the Great Lakes Converted Coaches chapter (GLCC).  The parking crew was friendly and efficient and we “wheels down” (an aviation term) in our site by 2:30 PM with the coach set up and ready to use by 3:00 PM.

The reserved parking was an unusual feature of this rally, and an attempt by GLAMA to be as accommodating as possible in spite of the added complexity of this arrangement.  If you have not been to an RV rally, you won’t fully appreciate how nice it was to be able to park with “our group” without having to coordinate our arrival with everyone else.  Generally if RVs want to park together at a rally they have to arrive together in a caravaan.  The only aspect of their parking that is usually pre-arranged is the area of the facility they will be in based on the hookups (electricity, water, sewer, generator use) they have paid for as part of their pre-registration.  Even with a small number of RVs caravaning can be a challenge.  Wile some rallies provide an arrival area where RVers can meet up and form their caravan, many rallies do not have the space for this.  In that case, the RVers first have to find a place to rendezvous.  (Walmart is a popular choice, especially if folks are staying overnight there anyway.)  They then have to make their way to the rally site while trying to keep the group together at stop lights (which isn’t possible with more than two rigs).  GLAMA is to be applauded for trying this new approach.

Goshen is the county seat for Elkhart County, Indiana and the home of the Elkhart County 4-H Fairgrounds.  We had been to this facility once before for The Escapees RV Club Escapade in September 2010 and it is a nice facility for an RV rally.  Access to the fairgrounds is good, and the interior roads are more than adequate for large motorhomes (and converted buses).  The campgrounds can provide 30 Amp power and water for a large number of rigs (800+), and there are also some full hookup, 50 A sites.  There are many buildings and covered outdoor areas available for entertainment, vendors, seminars, and meetings.  And yet all of this is neatly contained in a surprisingly compact space that makes the venue very walkable while the paved roads make for good driving of toads and courtesy transportation golf carts.

This is the first Great Lakes Area Motorcoach Association (GLAMA) rally being organized by the officers and volunteers of GLAMA.  For many, many years the Great Lakes Area Spring Spree (GLASS) rally had served this purpose.  Held at the Berrien Springs, Michigan youth fairgrounds, GLASS was a nice rally at a nice venue held over Memorial Day weekend and consistently drew 800+ motorhomes until the last few years.  Unlike most FMCA area rallies, however, the GLASS rally was organized by the Michigan Knights of the Highway, the 4th FMCA chapter ever formed, and the oldest FMCA chapter still in existence.  MKH handled the registration process, and any financial benefit (or loss) went to them, not GLAMA.

GLAMA takes in Indiana, Michigan, Ohio, and Ontario Canada, so obviously it does not include all of the states that border on the Great Lakes.  Even so, it covers a large geographic area with lots of FMCA members.  GLAMARAMA 2014 is also slated for the Elkhart County 4-H Fairgrounds in Goshen, but the intent is to then rotate it to each state and Ontario for two years each.  That will entail more work for GLAMA organizers, but will open up the chance for more people to attend and build a stronger sense of ownership across the association.

Today was early entry day, so there were no official activities beyond arrival and registration/check-in.  Pat and Vicky Lintner were already parked at the GLCC area as Pat is the GLAMA VP for Indiana and part of the rally organizing committee responsible for all of the rally specific signage.  We pulled in next to Pat and Vicky, followed by Butch and Fonda.  Mike and Laurie Minnick pulled in shortly thereafter in their 1968 MCI MC-7 bus conversion.  Don and Sandy Moyer then arrived in their 1948 Spartan bus conversion.

[Note: The Spartan bus was built for three years, post World War II, in Sturgis, Michigan.  The owner/president of the company was the chief test pilot for the B-25 bomber.  All of the engineers and craftsmen came from the aircraft industry and the bus was designed/built much more like an airplane than a motor vehicle.  Only 57 Spartan buses were built and most of them ended up being used outside the U. S., including some used to make a 12 hour daily run from Damascus, Syria to Baghdad, Iraq and a 12 hour run back, making it the fastest bus line in the world at the time.  The Moyer’s bus was the last one built, a 28 foot model.  It was destined for a bus company in Wisconsin but they never took delivery.  It left the factory as a seated coach, was driven out of the factory, and the front tires came off the ground because it was too heavy in the rear end.  Within two years someone had purchased it, taken out the seats, and had it converted to a motorhome.  Many of the details suggest that it was “professionally” done, but the Moyer’s have not been able to track down who did the conversion.  It was eventually parked and left to rot for 35 years until Don and Sandy rescued it.  Based on their research there are no more than 12 of the original 57 buses still in existence and theirs’ is almost certainly the only motorhome.  Don worked 8 hours a day, 7 days a week, for 18 months to put it back in usable condition.  It is a truly unique RV.]

GLCC reserved space for eight motorhomes and the other three planned to arrive tomorrow. The chapter will have more members/rigs in attendance than that, but they will be parked elsewhere.  George and Sue Myers are parked within close sight of our group, but are located for their convenience in running the golf cart courtesy transportation service.  Don and Kathy Crawford from Ontario are in the VIP row as Don is a past president of GLAMA, which also entailed being the national vice-president representing the Great Lakes Area.  Ditto for Jon and Sondra Walker, who was the GLASS National Director until he moved on to become GLAMA President.  Jon was elected the FMCA Senior National Vice-President this past summer at the FMCA national convention in Gillette, Wyoming, so the number two national FMCA officer is a GLCC guy.  Ron and Meredith Walker, who just joined our chapter, are also here but are parked with the Frustrated Maestros.  Ron is a retired K-12 music teacher and is the conductor of the FMs.

Linda made something new for dinner: firm tofu slices pan fried with onions and Bar-B-Que sauce.  She served it on a sesame seed bun with a side of sweet corn on the cob and some Sam Adams Cherry Wheat beer to wash it down.  Sometimes simple is best.

 

2013_09_16 (Mon) Home Away From Home

Buses at Service Motors in Twelve Mile, Indiana.

Buses at Service Motors in Twelve Mile, Indiana.

Service Motors in Twelve Mile, Indiana has become something of a home away from home for our motorcoach, having spent quite a bit of time there since we bought it.  As I have mentioned previously, Butch is very handy and has lots of tools, including a machine shop where he can custom fabricate things if needed.  He has been very generous with his time, talent, and facilities, giving me a good place to work on our bus and helping me with it when I need it (which is most of the time).  We often stop there enroute to other places, especially rallies that Butch and Fonda are also attending.  Once again, we spent the day camped there.

Service Motors is Butch and Fonda Williams’ Crosley automobile parts business.  They are the only full-line parts supplier for these wonderful little cars, last made in the early 1950’s, and have an active customer base.  They rarely close their business, but decided they would for the week while we attended the FMCA GLAMARAMA13 rally in Goshen, Indiana.  (Butch and Fonda are basically the same ages as us and were married one day before we were.  They have run Service Motors for 20 years and would like to retire and move in to their 1989 MCI MC-9 NJT bus conversion, which they have done themselves from scratch.  The business and facility are for sale.)

Linda worked with Fonda on some accounting issues while Butch attended to various bus and business tasks.  I spent the day repairing a leaky fitting on the fuel return line from the Aqua-Hot to the fuel tank.  This fitting had been leaking since I installed it as part of the fuel polishing pump project.  It looked like a simple enough project, which meant it would take me most of the day; and so it did.

The fitting in question was on the lower end of a check valve (back flow preventer) at the back of a small compartment, which made access difficult.  (I mentioned this project in a blog post in early June 2013, and have an article about the Parker Fuel Polishing Module queued up to run in some future issue of Bus Conversions Magazine.)  The compartment was covered by a beauty panel with a door, so the actual access opening was even smaller.  “Luxury” motorcoaches often conceal functional systems behind “beauty” panels so that the bays look impressively sleek and shiny when the doors are opened.  What I see, however, is something that blocks my access to systems that I need to work on so I decided to remove the panel, permanently.  This is why simply projects take all day.

The panel was held in place by four “L” brackets concealed on the inside (of course).  I borrowed an angle drive from Butch which allowed me to remove the screws fairly easily.  However, when I installed the electrical feed and switch for the fuel polishing pump back in June, I drilled a hole through this panel, ran a wire through it to the pump, and mounted the switch on the outside of it.  I dismounted the switch and removed the ring terminal from one of the wires as it would not fit through the hole otherwise.  With the switch and wires out of the way I was able to remove the panel after cutting loose some old rubber caulk along the bottom edge.  This is why simple projects take all day.

The “compartment” in question is just the extra bay space at the business end of the Aqua-Hot.  In addition to the fuel polishing pump it houses the coolant expansion reservoir and fuel filter / water separator for the Aqua-Hot as well as the fresh water pump for the domestic water system.  Fortunately the cover on that end of the Aqua-Hot slides off easily after removing only three easily accessible screws (it happens occasionally).  This made access to the leaky fitting much better.

The fitting was NPT male on one end, for threading into the bottom of the check valve, and barbed on the other end for attaching the fuel return line from the Aqua-Hot.  Barbed fittings are designed for a one time, press on installation of a rubber line, i.e., once the line is pushed on it does not leak and it does not pull off.  To remove it I had to cut it just below the fitting.  I was then able to unscrew the fitting from the check valve.  I was fairly certain that this junction was the major source of the leak.  The threads still showed remnants of Teflon thread tape, but not much.

The other potential leakage point was the seal between the two halves of the check valve itself.  The check valve is a two-piece body with internal parts, and there is a gasket between the two pieces of the body.  I had inadvertently loosened this joint when installing the fuel polishing pump and had not been able to re-tighten it in place because of the limited access.  Although I had a spare check valve, I decided to try and tighten the one that was already installed as replacing it meant cutting additional tubing and un-threading/re-threading additional joints.

Butch’s brother John came over in the morning to help Butch (and me) with anything that needed to be done.  Butch had him change out the element on his main engine fuel filter / water separator while he worked on other bus and business issues.  Fonda split her time between business things and loading their stuff on their bus.  Even when they are closed, there is business to attend to.  By the time I finished my little project it was well into the afternoon.  Butch and Fonda worked a while longer and then we headed off to Rochester for dinner at Alejandra’s Mexican-American restaurant.  It was 9 PM by the time we got back to the coach and we headed off to bed.

 

2013_09_15 (Sun) A Re-tired Travel Day

We were up early today anticipating our departure, but also still having some things to do before we pulled out.  I switched the outside faucets to provide treated water (filtered and softened) and 125 gallons of fresh water on board.  I also checked and adjusted all of the tire pressures on the bus and the car while Linda finished loading food, coats, and toiletries.  In the past we have pulled the bus into the street and then hooked up the car for towing.  With the new pull-through driveway finally working as intended, we decided to hook the car up before pulling out.  This allowed us to do our light check before bringing the cats out and starting the engine.  (The cats do not like it when the engine is running or the coach is moving, so we wait as long as possible to put them on board.)

Ready or not, you reach a point where it’s time to go.  We’ve done this enough that we now accept that we will forget something and hope it is something small that we can do without or easily replace on the road.  The cats do not fall into that category, of course, so we put them on board, started the engine, and pulled out around 10:40 AM.  The driveway worked as planned and the bus made it out with the car attached with plenty of clearance.

We headed out our street to Hacker Road and headed south to pick up I-96 westbound from Grand River Avenue in Brighton.  (We would normally take M-59 westbound to I-96 westbound, but M-59 is under construction and traffic flow is not good.)  The trip to Twelve Mile, Indiana is about 250 miles and normally takes us about 5 hours including a stop for fuel somewhere along the way.  We decided to stop at the Mobil truck stop at M-52 and I-96, only 22 miles up the road, to top off the tank.  This ensured we would have more than enough fuel for the round trip and also operate our Aqua-Hot hydronic heating system and/or our genset if needed.

The weather was overcast with occasional light rain, but made for good traveling.  We prefer driving on partly cloudy days as it is easier on the eyes.  Being Sunday morning, traffic was light, which also made for good travel.  Sunday morning is a preferred travel time when we can do it, especially if we have to go through a major metropolitan area.  The drive was uneventful and we arrived in Twelve Mile around 3:45 PM.  We got the car unhooked and backed into our space next to Butch and Fonda Williams’ MCI MC-9 NJT bus conversion.  (NJT stands for New Jersey Transit.  These buses have a special front cap with a destination sign above the windshields.  They were specially built for the New Jersey Transit Authority and used as commuter coaches throughout the state.)  Butch and Fonda have a large paved area where they keep their bus with room for two more if needed.  A year or so ago I helped Butch wire up a pair of “50 Amp” RV electrical outlet boxes, so we have a nice electrical service when we are there.

Fonda returned home with Bell as we were arriving, and Butch returned from a gun show not long after while we were still setting up.  Butch and Fonda understand RVing etiquette, and left us along until we had “made camp.”  As soon as we were parked and the engine was off the cats reappeared from their travel spot under the passenger seat and were up looking out the windows.  They don’t seem to mind living in the RV, they just don’t like it when we move it around.

Linda and I had not met Bell before and the three women sat and visited while Butch and I did the same.  Bell went to fetch Bill and we met up with them for dinner at the Hibachi Grill Chinese buffet in Logansport.  It sounds like it was an easy enough day, but by 9 PM we were tired.  I was reminded that retired means re-tired, as in, “I was tired, and now I’m tired again.”  But it’s a good kind of tired; different from that associated with working a full-time, stressful job.