Slapped in the face by a wet kipper!

Yes folks, the wet kipper of reality just slapped me in the face. As I worked today, I discovered that the inlet thread on the barrels is the same size as the vent cap. I further discovered that it is the same thread as the average garden hose. What a fool I have been! I could have connected the shower directly to some garden hose, let it dangle to make the U bend (or S bend), put a T adaptor on the vent hole with the hose going into that. A separate piece of hose raised a bit would act as a vent and an overflow. At the bottom of the barrel, rather than having the inlet/outlet going into plastic piping, I could just have an ordinary faucet. I could have saved myself no end of effort, some welding and so on. It would also have meant the whole asembley would have been able to flex if the barrel swings a little. Not only that but it would have allowed me space to put a second barrel underneath the shower - with its own faucet.

Well, today started by my having to clear a space underneath the bus on which I could lie to work. The winters leaves had all collected on that side of the bus. A quick blow job later and the leaves were gone.

I looked underneath the bus and the ribs are just about perfect. It seems to alternate two opposing C sections and two box sections. The C sections I can easily drill into to install the attachments for the chains that hold the drums.

Visualising how to hang the drums, I found my cheap dollar store cargo straps are way too long and will probably need to be trimmed but I can see how the drums will hang. Knowing about the hose connectors lets me think more about adding that second barrel. On the other side of the bus, there's space for a white and a grey and possibly a black too. I'm not sure that I want to put a battery underneath though. It just seems that I won't be using that much power anyway. I thus have my eye on a different solution or different series of solutions.

In order to hang the barrels I need to put pairs of holes perfectly aligned. Three pairs of holes will do. Thus I made a small template to guide me for the second hole. Looking at the C section above, I should have no problem with the sections bowing under 125lbs weight. Indeed, given that I'm using three chains with each chain capable of holding 450lbs and three turnbuckles each capable of holding 130lbs plus other bits that are pretty darned strong (can't recall the specifications), I think I have plenty spare capacity. The most I can reliably say it'll stand is three times 130lbs (the strength of the turnbuckles) so 390lbs. Of course I'm unlikely ever to reach more than 125lbs given barrel capacity.

Underneath the bus, I set to and drilled three holes - one for each chain that will pass around the barrel. The second hole posed more of an issue. I had no 5/16 bolt to bolt my template to the first hole. Oh, I haven't told you about the template. I made a template that matched the two sides of my U bolts as shown in the photo.

So, without using the template my first hole was not quite in the right place. I had to do a lot of filing to make it right! And of course prudence being the better part of valor, I departed to Lowes (hiss, spit) where I picked up not only a pair of 5/16 nuts and bolts but also some Thread Locker. That's useful stuff that is painted on a bolt then the nut is tightened and the nut then does not come undone without a significant fight. Just the thing for under bus usage!

While in Lowes, my phone rang with an unfamiliar out-of-state number. I didn't answer but let it go to voicemail. Then when I listened to the voicemail, it was a woman I vaguely remembered trying to help in the past. Eventually figuring out her phone number since Google Voice had screwed up pretty badly, I returned her voicemail. A few minutes later, she rang back. During the ensuing conversation I remembered her as being particularly needy and so the daylight escaped as I made multiple attempts to excuse myself, politely. Eventually after 40 minutes I did get away but the daylight had gone.

Undaunted I grabbed my lantern and an S hook and slid under the bus. Blow me down if the lantern trick didn't work. It was phenomenal! I used my bolt and template and made two very successful holes in just the right places. It was I felt too dark to work on the other side though so I packed up and came inside. Tomorrow it is alleged to be going to rain so I might get under the bus in the morning to drill the other six holes (and rust proof them).

The first barrel could be well hung by tomorrow night. Having said that, I'm rethinking my plumbing ideas since the barrels have hosepipe fittings. I did look at some faucets today but did nothing further. I want to let my ideas and thoughts gel overnight. It could well be that while a better solution exists, it would be financially better to stick with existing plans and just modify them a little bit. Being able to use flexible tubing would be a good thing as it allows the barrels a little movement.

The new plan

Today I went onto the bus and fixed some warped hardboard which had warped due to the water ingress from the leaking roof last month. The door between the cockpit and the galley needed adjustment too. That had been badly warped but now it works correctly.

Thinking about the battery carrier problem, I realised I might have been overreacting. Thus, today I went ahead and got some more tools from Harbor Freight. I'd been in need of a better rivet gun and of some deep sockets so I picked those up. A welder was not on my list this time.

The rivets should have a sheer strength of 900lbs which means plain rivets should work. I'll have to see if the bolt holes are too big. If they are then I'll use 1/4x20 bolts instead. Otherwise, I'll try rivets.

Meanwhile, I'm looking into two other things. The first is super capacitors and the second is thermo electric generators. In order to power a microwave for 20 minutes, I'd need 1200w at 110v. Given the losses from an inverter of around 15%, the power supply at 12v would have to provide 12,650W. Given that my favourite battery would provide 500CCA, I'd need a bank of at least 14 in order not to overload any of the batteries. That would cost at least $1,000, weigh at least 700lbs and take way more space than there is space available.

Super capacitors can provide a lot of power quickly. They're not as energy dense as batteries but the idea is that if they could provide a 20 minute burst of power, they could be backed by just one lead acid battery. The task now is to find a super capacitor setup that can provide sufficient power.

As far as thermoelectric power generation is concerned, I have a feeling that like most non gasoline powered generators, its going to be expensive or worthless in terms of power generated. The two methods under current investigation are Stirling generators and Peltier generators. Stirling generators use magnets and coils together with a closed air system. Peltier generators use heat difference to generate power.

Disappointment

Today I commenced work, rather late in the day to complete the battery compartment. After tightening a few nuts and cropping the overlong bolts, suddenly one bolt shattered under very light pressure.

Given that when asked, the store (Fastenal) claimed the bolts to be easily capable of holding 200lbs and probably good for 1200lbs, I'm rather disappointed. Needless to say, with a bad bolt, the whole batch must be condemned as suspect, particularly when it cannot fail. If the battery compartment failed, the consequences could be fatal.

Looking at the compartment so far, the angle bracket that came from the bunk beds that I'd previously condemned is probably 87° rather than 90°. This makes construction of a regular shape somewhat awkward.

Clearly this will have to be rebuilt. I think, sadly, it will have to be welded which is beyond my skills. Given that, I suspect it would be better to let the welder supply the steel as he would likely have access to better quality steel of a more appropriate style.

Generally, I find everything the Hillbillies installed in the bus was of pretty low quality and unusable in any shape or form. In many ways, it would have been better to have started with a bus that still had seats in it. Having experienced the conversion so far, I think I'd do it very differently next time. Having said that, I'm almost completed. I just need to add water tanks and the battery compartment. Then, there's very little else to do.

I had hoped to be able to do everything underneath myself but without welding skills, that's not possible. It's probably cheaper to get somebody else to do the welding than to buy a welder and to waste time learning how to weld. Given that I need the bus operational, I'm going to have to ask about welding. I hate having to use somebody else in my self build project.

On the path of Houdini

Houdini could open any lock. I'm almost there myself with the front door locking mechanism. Today my electro magnet arrived from China.

The magnet apparently runs off 9v so after a long hunt I located a pp3 battery. It was inside a radio transmitter detector that had been lurking in my drawer since I'd had to track down some unauthorized listening devices in my old home. The battery was several years old yet it powered the magnet very successfully. Indeed, it even grabbed onto the door locking mechanism strongly enough for me to lift the latch.

As the magnet didn't seem to have much grabbing range its probably going to be best used as a repelling magnet. I'll mount a permanent magnet on the underside of the latch and the magnet can repel it in order to lift the latch. That's the plan anyway.

Also arrived today was my Nema 5-15P socket. I tried it with my plugs and it all worked perfectly. Now all I have to do is to rebuild the battery/cable compartment. I tried both plugs and they both fit nicely into the socket as can be seen from the combined socket, plug photo.

Speaking of the battery/cable compartment, the bolts and lock nuts arrived that are intended for use in the new compartment. I'd been afraid they'd be too thin but looking at them, they'll be fine. I'll use many more than I think I'll need, just for security.

I can't find the sheet strength for the bolts but given the entire weight that needs to be supported will be probably 20lbs for the compartment frame plus 55lbs for each of two batteries plus say 30lbs for luck then doubling it all in order to allow for rough roads. That's a grand total of 160lbs. Assuming each bolt will bear 10lbs then 16 would be needed. An unverified online source states 200 lbs sheer strength per bolt. That sounds doable. Another online source quoted 700lbs. I'm being conservative and reckoning 20lbs per bolt. I don't want 160lbs of battery compartment falling on the ground!

How disheartening!

Today I went to the bus with the intention of painting the roof. It seems the Rustoleum on the roof is now beginning to peel. More areas of the sides are peeling too. Clearly there's something amiss with the Rustoleum. Indeed, I contacted Rustoleum and they agreed it shouldn't be peeling and bubbling and announced they were sending some form of refund. Obviously they must know something about that batch for them to be sending a refund.



That was pretty disheartening. I have a small pot of grey Rustoleum that I was planning to use to complete the roof painting. Having seen all that, I've decided I'm not going to waste my time putting more Rustoleum up if all its going to do is peel. Clearly at some point I'm going to have to repaint the whole bus. It kinda spoils the effect but I need the bus completed, paint is something that can be left til last.

Meanwhile, my battery powered shower unit arrived as did my Harley Davidson ignition switch. They're waiting on my unlocking gizmo and my completing the plumbing.

The water tanks are proving troublesome to obtain. It seems to cost $20 a tank for shipping. Secondhand 15 gallon tanks seem to be $20 which is ludicrous for something that's only $40 brand new. I have a feeling I'll end up driving to the manufacturer in Georgia to get brand new tanks. It's 200 miles in each direction. At 19mpg and $2 per gallon, that's going to cost $42 or the cost of shipping two barrels.

Given the ludicrous cost of standard water tanks, even with the ludicrous shipping costs and having to buy new barrels they still work out cheaper.

A few days ago, I bought a lot of cheap 10-24 nuts and bolts. Those might be good enough to hold the forthcoming battery compartment together if enough are used. They're each apparently capable of 55 kilograms. Its hard to find good figures for bolt strengths online. So many sites are such unreliable garbage. I'm sure I have a mechanical handbook somewhere. There's no rush though as I haven't cut all the steel yet.

Speaking of cutting steel, that was another task that never got done today. In order to paint the roof, I had to move the bus. In order to move the bus, I had to start the engine. Oops! Flat battery. Clearly either I have a bad battery or something is draining it. Thus, the battery is currently on charge.

So, the sum total of today is nothing. I got depressed and that's about it. With luck, tomorrow should be better.

Nothing much

Today was a day when I didn't even enter my bus. I did, however, manage to get 200 two inch 10-24 bolts online for less than 3 cents each. They're zinc plated ordinary steel with a strength of 700lbs. I did get some nylon insert lock nuts to go with them. If need be I can get ordinary nuts cheaply at Home Depot. That's if I find out necessary to pair a nut with a lock nut.

The heaviest thing the bolts will be supporting is two 50lb batteries plus the compartment. I'll be fastening everything in multiple locations so I'd imagine by the time I've built it, I could probably lift the bus using it. I tend to build things strongly.

The neat thing about the bolts is that unlike steel rivets I don't need to buy an expensive extra riveter to employ them. Steel rivets cost more than the bolts did and of course aluminum rivets just aren't strong enough. If I need an extra spanner, they're dirt cheap. Basically, the bolts are a tried and trusted low cost option.

Meanwhile my battery powered shower arrived. It looks to be of decent quality though only time will tell. I'll probably test it tomorrow. The big hold up now is those blasted water tanks. As I said, those are probably going to be my biggest problem.

I contacted a couple of companies selling new 15 gallon barrels and not one responded. Clearly business must be so good that they can't handle more. Either that or its yet another example of US customer service leading the world in suckiness.