ZMotorsports Shop Projects 2.0

[zmotorsports]

Smart move Mike. I know you mentioned before about the stress of going back into debt to buy a different house and build a new shop. I was kinda surprised you even toyed with the idea of a new coach at this point in time.



In the long run, I'd imagine better sleeping at night keeping the current coach rather than ante up a stack of Ben Franklins.









So when the coach is parked/plugged in, the water heater is running off electric. When that's not available, it burns diesel rather than LP to heat the water ? So does it use the main fuel tank or is there a secondary tank ?

You’re right Eric, I definitely don’t want any more debt at this point in my life. Once the house is paid off and closer to retirement we'll more than likely look at upgrading one last time. Hopefully by then we can be able to do a cash purchase which will even be better.

As for the heater, the Aqua-Hot setup in my coach has a boiler tank that contains glycol. The glycol is used to transfer heat to the domestic water system for heating my water as well as flowing throughout the coach to a series of heat registers that also provides quiet, comfortable and even heat to the coach’s interior. The glycol is heated by either a 1650 watt electric element or a diesel burner that draws fuel from my main 150-gallon fuel tank. My 10kw Onan generator also draws from the main fuel tank.

When camping and hooked to shore power most of the time the electric element is enough to heat the glycol as long as outside temps are in the forty’s or more. When the temps drop and I need heat inside the coach as well as hot water the diesel burner will ignite.

On my model of Aqua-Hot both the electric side and the diesel side have two thermistors (Klixon)each. One for low temperature to activate and one high temperature to cutout. The nice thing about mine is that the diesel low temp Klixon is a few degrees lower than the electric. This means that as the temperature of the glycol drops the electric element will activate first. IF the glycol temperature rises it will merely rise until the electric high temp Klixon deactivates the electric element. IF the electric element doesn’t provide enough heat and the temperature of the glycol continues to drop and reaches the preset temp of the diesel Klixon then the diesel burner will ignite and both will heat the glycol.

On my system I usually just leave both the switch for the electric and the diesel on so it will work as I described above. On the newer model Aqua-Hot Systems they don’t work that way and share Klixon temperature switches so both systems come on simultaneously once the glycol temp drops enough that heat is required.

Hope all that makes sense. It really is a nice system and provides very even and quiet heat inside the coach. Aqua-Hot was on our list of “must haves” when we were looking at upgrading back in 2007 as I fell in love with them when I worked on a few for friends. As much as we use our coach in cold temperatures I would never have another coach without Aqua-Hot. Also worth mentioning is that our coach has heat registers in the basement as well to keep the tanks from freezing for a true all-weather coach. We’ve used our coach down into the single digits and been quite comfortable inside.



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[zmotorsports]

I was able to spend some quality time working in my shop today. It is so nice to have it setup and everything in its proper place to be able to walk to a cabinet or drawer and get what I need.

I performed the service on our Cummins ISL in our coach today. Oil, oil filter, coolant filter, primary and secondary fuel filters.


Oil and coolant filters changed.


Primary fuel filter changed.


A lot of debris in the sediment/Water separator bowl for some reason on the primary filter.


While I was waiting for the oil to drain from the engine I tackled another quick project. My switch box for my A/V keeps coming loose from the double sided tape and rattling around in the cabinet plus it’s a PITA to hold with my right hand while activating the buttons with my left and chasing it around the cabinet when parked.

I came up with a plan to make a wedge type device to hold the switchbox in place. It started with a piece of 1/2” square tube and a piece of 10-gauge strap.


I put the square tube in the mill and cut .080” off to remove one side and land at approx. .400” and have a U-channel. I then cut the 10-gauge strap to fit inside the channel.


Then I turned the channel over in the mill vise and drilled & tapped a 10-32 hole about a half inch from either end.






Beadblasted and painted semi-gloss black to match the A/V components.


Here you can see the completed wedge. It is placed on top of the switch box in the small gap between it and the top of the cabinet. The socket head screws are threaded in thus pushing the 10-gauge strap up against the top of the cabinet and the channel down against the switch box in which is pushed down onto the double sided tape and firmly holding it in place. No more chasing it around the cabinet when pushing the buttons and no more rattle.



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[rmack898]

Mike,
I sometimes look at pictures of your shop and think I'm looking at my shop, although I must say yours is much cleaner than mine.

Between the welding table clones and now seeing my height gauge on your surface plate, I sometimes get confused although that is not difficult for me.

I also picked mine up at an estate sale along with a very nice sine plate for $50

 

[kbs2244]

That "While I was waiting" project deserves a thread of it's own.
Good thinking, as well as good work.

 

[zmotorsports]

Mike,

I sometimes look at pictures of your shop and think I'm looking at my shop, although I must say yours is much cleaner than mine.



Between the welding table clones and now seeing my height gauge on your surface plate, I sometimes get confused although that is not difficult for me.



I also picked mine up at an estate sale along with a very nice sine plate for $50

That’s awesome Mac. I’d love to see some pics of your shop.


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[zmotorsports]

That "While I was waiting" project deserves a thread of it's own.

Good thinking, as well as good work.

Thank you, I appreciate the compliments.

Thanks for following along on my projects thread.


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[NUTTSGT]

Thanks for the explanation of the heating system Mike.

Also, love the old school in the coach....some members may not know what a VCR is.

 

[zmotorsports]

Thanks for the explanation of the heating system Mike.

Also, love the old school in the coach....some members may not know what a VCR is.

Believe it or not Eric, we actually still have some movies on VHS and it works great so no reason to remove it at this time. That may change when it craps out but no harm in packing it along on trips at this time.

Thanks for following my projects thread Eric.

 

[NUTTSGT]

Believe it or not Eric, we actually still have some movies on VHS and it works great so no reason to remove it at this time. That may change when it craps out but no harm in packing it along on trips at this time.

Thanks for following my projects thread Eric.

No worries Mike, I have a combo VCR/DVD player in the garage....I still have a stack of movies on VHS also. It's nice to break one out every now and then.

 

[ttpete]

No worries Mike, I have a combo VCR/DVD player in the garage....I still have a stack of movies on VHS also. It's nice to break one out every now and then.

I have the "Godfather Saga" set on VHS. It was made by combining Godfather 1&2 so everything is in chronological order. It's never been made in DVD as far as I know.

 

[NUTTSGT]

I have the "Godfather Saga" set on VHS. It was made by combining Godfather 1&2 so everything is in chronological order. It's never been made in DVD as far as I know.

Yep, in a box set. 1, 2, and 3.

 

[Wanna Ride]

The VCR just made me chuckle.

As I stare at mine sitting on the shelf in front of me, in my shop, just above the stereo I'm listening to as I type this. I just realized that I haven't turned it on, in at least a decade. Maybe even fifteen years.

 

[zmotorsports]

I got home late again tonight and didn’t feel like creating a mess and starting another project so I pulled up a stool and watched my son as he ran a couple of mock programs on his CNC mill.


I’m getting as excited as he is to see some chips. Unfortunately I don’t think it will be for a couple of weeks as he found out today he has to go out of town for training and will be gone for at least a week.


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[Boosted1]

Great updates.
Thanks for sharing and providing my morning coffee read. Much better than the news.

 

[zmotorsports]

Great updates.
Thanks for sharing and providing my morning coffee read. Much better than the news.

Thanks Boosted. I'm glad you tune in to my projects thread and enjoy it enough to come back.

 

[C_F]

That "While I was waiting" project deserves a thread of it's own.
Good thinking, as well as good work.

I was thinking "it must take a long time to drain that oil pan".

 

[zmotorsports]

I was thinking "it must take a long time to drain that oil pan".

It actually does, it usually takes about an hour or so to drain all 28 quarts from the pan. This is why when planning the servicing of the coach I generally have a secondary project planned to occupy my time waiting. I just keep an eye on that first 5-gallon bucket especially so it doesn't overflow. Once I swap them around I can walk away and forget about it because I know I'm safe from an overflow.

The timing on this one was about right. I was applying the paint by the time the oil was about done draining. Pretty good timing.

 

[sanddan]

Funny to see the VHS player. After hauling mine around for years without using it (we have a blue ray player in our coach) I gave it to goodwill along with most of the tapes.

 

[C_F]

It actually does, it usually takes about an hour or so to drain all 28 quarts from the pan. This is why when planning the servicing of the coach I generally have a secondary project planned to occupy my time waiting. I just keep an eye on that first 5-gallon bucket especially so it doesn't overflow. Once I swap them around I can walk away and forget about it because I know I'm safe from an overflow.

The timing on this one was about right. I was applying the paint by the time the oil was about done draining. Pretty good timing.

I see, sounds like a good plan then to have another project to play with while you're waiting. Out of curiosity, what sort of oil change intervals do you have with your coach? With that much oil, I imagine it's quite a lot of miles between oil changes.

 

[zmotorsports]

I see, sounds like a good plan then to have another project to play with while you're waiting. Out of curiosity, what sort of oil change intervals do you have with your coach? With that much oil, I imagine it's quite a lot of miles between oil changes.

The Cummins maintenance intervals call out for oil changes @ 15k miles, coolant filter changes @ 15k miles, primary fuel filter @ 20k miles and secondary fuel filters @ 40k miles.

I generally shoot for filter and fluid changes every other year which generally equates to around 10k-14k mile range. At that time I replace all of the above, including both primary and secondary filters. Probably a bit overkill but I'm ok with that.

 

[GRN96WS6]

What does an oil change and filter/flush cost, curious.

 

[WhiffySpark]

We charged 250-300 for an oil change.

I hated doing them

 

[zmotorsports]

What does an oil change and filter/flush cost, curious.

For everything I️ listed it was right around $400. I️ change out my air filter every other oil change and it wasn’t due so I️ didn’t change it this round.

The fuel filters are quite spendy but not worth taking chances with the pressures these systems pushing through the injectors.


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[zmotorsports]

Tonight I️ hung up my American flag in the shop. My son bought this flag for me last year but I️ didn’t hang it in our old shop due to the move so I️ decided what better time to hang my new flag in my new shop than Veteran’s Day.




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[zmotorsports]

Before closing up shop tonight I️ snapped a couple pictures of the view of my mountains to the east out of my shop windows.




What a great view of the mountains out either of my shop windows.


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[GRN96WS6]

For everything I️ listed it was right around $400. I️ change out my air filter every other oil change and it wasn’t due so I️ didn’t change it this round.

The fuel filters are quite spendy but not worth taking chances with the pressures these systems pushing through the injectors.


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Not bad for every other year.

 

[zmotorsports]

Not bad for every other year.

I️ agree. As far as routine LOF a couple hundred bucks a year isn’t bad. It’s all of those “other” little things that add up.[emoji15]


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[zmotorsports]

I️ had about an hour yesterday morning so I️ ran out to the shop and knocked out one of the door frames for my workbenches.

Frame welded together and set into the opening to place the hinges.


Opens and closes smoothly.


Fairly nice consistent gap around the perimeter.


I️ have one more frame to fabricate for the L-shaped workbench then I’ll have to dig through my slim assortment of sheet and see what I️ have available. I️ hope I️ have some aluminum and won’t have to purchase anything.


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[zmotorsports]

Completed the second workbench cupboard door today.




If I can get home before dark tomorrow (daylight savings time ending really *****) maybe I can get the door frames painted.

Then I can get some aluminum cut for the exterior of them and riveted on.


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[zmotorsports]

After opening and closing the work bench doors a few times last night, I think I may add a piece of .125" x 2" flat strap vertically down the hinge side to add a bit of rigidity to the framework. It seemed a bit more flimsy than I like, although I know it will have strength added with the aluminum sheeting I think the flat strap will help a lot.

Then it looks like I need to get my snowblower out of the garage and bring it into the shop for a once over. The news stated this morning that we could have our first snow on the valley floor on Friday and I don't want to be caught off-guard.

 

[shortykorte]

Ok I'm confused. The door in corner appears to have hinges on both sides. Also what are you using to keep doors closed, magnetic catch?


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[zmotorsports]

Ok I'm confused. The door in corner appears to have hinges on both sides. Also what are you using to keep doors closed, magnetic catch?


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It may just be the way the picture is. The door in the corner is hinged on the left if looking at the picture. The component you can see on the right in the same picture is the magnetic catch. It does kinda look like another hinge but only hinged on the left, both are actually hinged on the left.

Thanks for looking so in-depth and for following along Shorty. It's nice to see people take such interest that you're looking that hard.

 

[shortykorte]

Thanks. Guess I wasn't looking to close. The earlier picture clearly shows the magnetic latch. My bad. Lol

Quality work is always worth getting a good look at.


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[zmotorsports]

Thanks. Guess I wasn't looking to close. The earlier picture clearly shows the magnetic latch. My bad. Lol

Quality work is always worth getting a good look at.


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Thanks Shorty, I appreciate that.

 

[C_F]

The news stated this morning that we could have our first snow on the valley floor on Friday and I don't want to be caught off-guard.

I'm sure not looking forward to that ****. Oh well, I know we've been very lucky to have the decent weather we've had so far.

The doors will look nice when you're finished!

 

[zmotorsports]

I'm sure not looking forward to that ****. Oh well, I know we've been very lucky to have the decent weather we've had so far.



The doors will look nice when you're finished!

Thank you.

I’m not ready for that white **** either, I sure hope it’s not like last year, the winter that wouldn’t end. I’m sure last year was because I was trying to get my shop built though. [emoji15]


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[zmotorsports]

I was able to get some more work done on my work bench cupboard doors tonight. Welded some strap down the hinge side to give a little more support then wiped down and painted with Rustoleum Hammered paint to match the benches themselves.









I also scrounged through my limited supply of aluminum sheet and found some 16-gauge brushed aluminum that is just enough for the two doors but not enough for the one side of the storage compartment on the 6’ bench. I was able to also find some 16-gauge polished ATP but seeing as how I have nothing else in the shop that is ATP nor polished I think I will install the ATP with the flat side out and tread in so it more closely matches the coloring of the sheet on the doors.


While the paint was drying on the door frames I took my patio furniture from the deck and put it up on the mezzanine so it will be out of the weather throughout the winter.

Tomorrow I will work on getting the aluminum cut as well as get my snowblower ready for that white ****.

 

[customh]

Very nice Mike. Watched a selection of the videos and looked through the whole thread Saturday. I just began last year as a maintenance technician, so hopefully your success is a sign of things to come for me. Not without lots of hard work and dedication of course.

 

[zmotorsports]

Very nice Mike. Watched a selection of the videos and looked through the whole thread Saturday. I just began last year as a maintenance technician, so hopefully your success is a sign of things to come for me. Not without lots of hard work and dedication of course.

Thank you for taking the time to read through the thread and especially for watching my videos. I hope you have found them informative.

Congratulations on your new career. I hope you find it as rewarding as I have in the 30 years I have been a maintenance mechanic.

 

[zmotorsports]

Although I was going to finish up my cupboard doors tonight and get my snowblower checked out, plans just changed.

My upholstery guy just called me and said if I could get my Jeep seats to him tomorrow he could possibly get on them Friday and finish them up Monday at the latest. He also said he had a cancellation for next week and if I could get my coach seats/couches to him by Monday he will more than likely be able to jump right on them.

When I talked to him last week about my two front seats in the Jeep and my coach interior he told me he could more than likely get the Jeep seats done right after Thanksgiving but he has two large jobs coming in right after the new year and would try to get my coach done by Christmas but couldn't make any promises. I was shocked when he just called and asked if I could get everything to him this soon. I hope he has my coach interior finished up by the first part of December, that would be great.

Next couple of nights will be spent removing interior.