Category Archives: Indiana

Posts related to our RV-related travels in Indiana.

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.

 

2014/06/29 (N) Lilly And Company

We said our “goodbyes ’till next time” to Linda H., Ron, and Mary last night as they went off to bed.  Linda and I were up at 7 AM CDT and had the car loaded by 7:45.  Marilyn was also up so we got to visit and say goodbye to her before we left at 8 AM.  We got back on I-270 westbound and headed to Bridgeton, Missouri where my sister lives.  We stopped at the St. Louis Bread Company bakery cafe on St. Charles Rock Road for coffee and bagels first and arrived at Patty’s house a little after 9 AM.  St. Louis Bread Company is the original name of the Panera bakery cafés, and they still use the original name in the St. Louis market where the company started and is still headquartered.

Patty’s house was completely destroyed two years ago April in the Good Friday tornados that swept through the St. Louis, Missouri area.  The outbreak damaged over 700 hundred homes as well as the St. Louis Lambert International Airport.   This was a newsworthy weather event, and Patty was interviewed by The Weather Channel, but little did anyone know at the time that it was just the first of what would prove to be a very bad season of much worse tornado outbreaks across the south.  It took a year to rebuild Patty’s house and she made a few changes in the design that resulted in a nicer, more livable dwelling, a small consolation for everything see lost.

Patty’s daughter, Amanda, came over around 10 AM with her daughter, Lillian Lissette.  Lilly is only six weeks younger than our grand-daughter Madeline, so developmentally they are doing similar things.  Lilly is up on two feet and very mobile.  She is a very sweet little girl who is curious about everything and is verbalizing a lot without actually saying anything.  She has all her baby teeth and an infectious smile.  She walked over to Linda as soon as she saw her, arms outstretched, and gave her a big hug.  Apparently that is not something she does with people she does not know well, so it was a very special moment that surprised her mom and grandmother.

Patty is down to just one dog, Maggie, from the three that she had for so many years.  She lost Bootsie (17) and Rosie (14) last year which was especially hard given that they survived the tornado.  She also lost Angel, a white female cat our mother had adopted and was another survivor of the tornado.

We visited as long as we could, including staying for a light lunch of fresh fruit.  We would have liked to stay longer but needed to get back to our house today.  Although Linda did not have to report for jury duty on Monday morning, she did have to go back to the dentist to have a new mold made for her crown.  We were also expecting our landscape contractors around 8 AM and would need to move the bus out of their way.

We were back on the road and headed for home at 12:30 PM CDT.  We went back the way we came: I-270 E (MO) to I-270 E (IL) to I-70 E (IL) to I-70 E ( IN), to I-465 S (IN) to I-69 N (IN) to I-69 N (MI) to I-96 E (MI) to Latson Road N to Golf Club Road E and finally to the dirt roads that signal we are almost home.

Linda has a nerve in her right hip that is giving her a problem, especially when she sits for any length of time.  She keeps a tennis ball in the car and puts it under her hip to relieve the pain.  Saturday morning she and Mary went for an early morning walk and she pulled a muscle in her left hip.  She was having difficulty sitting comfortably and we agreed that I would drive home in order to allow her the flexibility to change her position as needed.  She also took some pain medication that rendered her unsuited to driving.  On the plus side, she got to nap on the way home.

The trip took almost 10 hours including several rest stops and a stop in Fishers, Indiana for fuel and dinner at Panera.  We brought an assortment of audio CDs with us but did not play them on the drive down as we had a lot to talk about (when I wasn’t napping).  We did, however, play them on the way back to help keep me entertained and awake.  We pulled into our driveway a little after 11:00 PM EDT.  Linda made popcorn while I unpacked the car and brought everything inside.  The cats were glad to see us once they determined we were not scary alien creatures invading their house.  We enjoyed our popcorn snack and then checked the phone messages just in case there was something important.  There wasn’t so we went to bed.

 

2014/06/26 (R) Westward Ho

We were up by 6 AM and started loading the car for our trip to St. Louis, Missouri.  Breakfast consisted of a banana and orange/grapefruit juice to wash down a pill and a vitamin.  We had planned to leave at 8 AM (EDT) in order to arrive in Glen Carbon, Illinois around 4 PM (CDT). We had the car loaded and the house secured by 7 AM and decided to hit the road.  We took Golf Club Road over to Latson Road and stopped at Teeko’s to pick up coffee and a couple of bagels.  A short distance south from there put us at the new Latson Road interchange on I-96 where we headed west towards Lansing.

We picked up I-69 at the southwest corner of Lansing and headed south-southwest towards Indiana.  About half way to the border we crossed I-94.  From that point on our route was one we have driven many times in the car over the last 38 years.  We stayed on I-69 to the northeast corner of Indianapolis and then continued down the east side of the metropolitan area until we got to I-70.  We took I-70 through the heart of the city and out the southwest corner.  From there we continued on I-70 westbound all the way to the Glen Carbon/ Edwardsville, Illinois exit.  In spite of our morning coffee stop, several stops at rest areas, and a stop for food and gasoline, we arrived in Glen Carbon at 3:35 PM CDT.  As we did not expect anyone to be home until 4 PM we drove into Edwardsville and stopped at Walgreen’s ad Walmart.

Linda eventually exchanged text messages with her sister, Marilyn, who let us know that she was home from work.  We were there not long after 4 PM and had our welcome greetings with Marilyn and the three dogs.  We unloaded our car, got everything situated in our room, and settled in for a chat while we waited for Linda H., who owns the house, to get home from work.  She eventually did and we had more greetings and more talk.  By 6:30 PM everyone realized they were hungry and we went out to dinner at the Pasta House restaurant in Edwardsville.  Linda and I had a veggie pizza without cheese.  The crust was thin and a bit crispy, the way we like it, and the pizza was loaded with lots of good vegetables but not too much sauce, also the way we like it.  We both had a small garden salad to go with the pizza and it was all very good.

When we got back from dinner we got the wireless networking turned on and our various devices connected and working.  We settled in for more conversation in the kitchen while Linda made her vegan double chocolate torte which we will have for dessert with dinner tomorrow night.  Eventually everyone was tired and retreated to their respective bedrooms.  We watched another episode of Doc Martin before turning off the lights.

 

2914/06/20 (F) Couch Potatoes

Over the last few months I managed to connect our friends and fellow Prevost H3 owners, Chuck and Barbara Spera, with our friends and fellow Prevost XL owners, Pat and Vickie Lintner.  Chuck was looking for a sofa to replace the one in their motorcoach and Pat and Vickie had one they were looking to sell.  Today was the day for consummating the deal, which necessitated a road trip from the Detroit, Michigan area to the Elkhart, Indiana area to pick up the couch, pay for it, and bring it back to Chuck’s shop.

Chuck and I drove down in his Ford Excursion.  I went along to keep him company, for the opportunity to catch up on a lot of conversation, and to help load and unload the couch.  We arrived in Elkhart just after noon and grabbed a quick bite to eat at Burger King.  I had French Fries, thus today was about couches and potatoes.

While I was away on the road trip, Linda went to Ann Arbor to visit our 18 month old grand-daughter and her parents (our son and daughter-in-law).  By dinner time we were both tired so we had Amy’s Pad Thai and turned in to watch two episodes of Doc Martin.  We did not get to watch any episodes while we were at the rally in Goshen, Indiana so we are catching up.

 

2014/06/15 Family Time

We were parked in a fenced compound area next to the regular “campground” at the Elkhart County 4-H Fairgrounds.  The campground has gravel sites with 50A full hookups, and we were allowed/encouraged to use the sewer connections to dump our holding tanks before departing this morning.  We had checked out the campground last night and decided that it would be easier for us to pull around to the dump stations on the outer road than to maneuver into and out of one of the open campground sites, all of which were back-ins.

I have mentioned before what a nice facility this is.  Several of our GLCC members are from north central Indiana and explained to us that the fairground is as nice as it is because it is booked every week for most of the year, winter being the exception.  Elkhart is considered the center of the RV industry in the U.S., but the reality is that RV-related industry is located throughout north central Indiana, and a little bit of southern Michigan, with a few facilities in other parts of Indiana and Ohio.  There is also significant RV industry in California, Oregon, and Florida, and to a lesser extent in Pennsylvania and Alabama.  By “RV Industry” I am referring to manufacturing, not RV parks, resorts and campgrounds, or RV dealers and service facilities, which are obviously located all over the place.

We skipped breakfast and coffee, as we always do on travel days.  Linda prepared the inside for travel and then we visited for a while with our GLCC friends.  Around 9:00 AM I unplugged the electrical power, stowed the cord, turned on the chassis batteries, opened the air valve for the engine accessories, and fired up the engine.  I did not have any trouble getting out of our parking spot or the compound.  I drove over to the dump station, which can accommodate nine RVs at one time, and Linda followed in the car.  While the holding tanks were emptying we hooked up the car for towing.  With everything stowed and secured for travel we checked the toad controls and lights and were on our way, exiting the fairgrounds at 9:25 AM.

We followed the same route home that we used when we left the Escapade rally a month ago: CR-34 (Monroe St.) east to CR-29 north to IN-4 east to IN-13 north to US-20 east to I-69 north to I-96 east to M-59 east and finally a couple of miles of dirt roads to our house.  We stopped at the Travel America (T/A) truck stop on M-60 at I-69 to put biocide and Stanadyne diesel additive in the tank along with 75 gallons of diesel fuel.

We had just over 1/4 tank of fuel indicated on the fuel gauge when we pulled in to the T/A.  If the gauge is anywhere near accurate that was approximately 50 gallons of fuel, enough to travel another 200 miles and still have 15 – 20 gallons in the tank; more than enough to get us to the Mobil truck stop on I-96 about 25 miles before our house.  I wanted to use as much of the fuel in the tank as I could before adding more but did not want to risk running out or sucking sediment off the bottom and clogging the fuel filters.  In the end we decided it was safer to stop and add fuel while we still had the 1/4 tank.  The 75 gallons brought the fuel gauge up to 5/8ths, which is what I expected.  The fuel tank capacity is 235 gallons, but I assume the full mark on the gauge corresponds to 200 gallons.  That makes every 1/8 of a tank on the gauge correspond to 25 gallons.  We also presume that our average fuel economy, based on prior data, is 6 MPG which equates to 150 miles per 1/8 tank.

We did not fill the tank because the bus is going to be sitting for a while and we did not want to have all of that fuel onboard aging in the summer heat.  There is a reason, however, to keep the fuel tank as full as possible.  Most of the fuel that is pumped to the engine is used to cool the injectors and the DDEC engine computer and returned to the tank. The more fuel in the tank, the less frequently any particular molecule passes through the engine giving the fuel in the tank more time to dissipate the heat.

Our trip was easy and un-eventful other than the powered driver-side windshield shade quite working.  Add that to the list.  We got home by 1:30 PM which gave us time to unload food and a few essentials from the bus and take showers.  Since Linda spent Saturday morning preparing food, she only had minimal cooking to do for dinner.  Our son, daughter-in-law, and grand-daughter arrived at 3:30 PM and our daughter and son-in-law arrived at 4:00 PM.  Madeline had a cold, wasn’t feeling well, and had only had a short nap, but she was fine as long as she was busy.  This was a combination birthday and Father’s Day gathering, but mostly an excuse to gather our small, immediate family.  We had a lovely summer meal of potato salad, collard greens cole slaw, baked beans, and cheeseburgers with chocolate cupcakes (from a local bakery) and fresh strawberries for dessert.  All vegan, and all delicious.

Brendan, Shawna, and Madeline left shortly after dinner and Meghan and Chris left around 8:00 PM.  Although our morning departure and drive home had been quite routine and the family gathering had been relaxed and relatively easy, it all added up to a long day.  I started the download of an update to my Adobe Creative Cloud subscription that looked like it was going to take a while, so we skipped watching an Episode of Doc Martin and turned in for the night.

 

2014/06/14 (S) Day 4 Rally Conclusion

Each rally has a slightly different approach to food.  On the last full day of the GLAMARAMA they switch the breakfast carbohydrate delivery mechanism from donuts to pancakes and serve them with sausage links.  The coffee and tea are still there, of course, so we had coffee.  Other rallies, like the Escapades, have a “hitch up” breakfast on the day of departure, with coffee and donuts.  When Nick and Terry Russell were running their Gypsy Journal Gathering rallies they also had coffee and donuts on departure day as I recall.

In order to serve a lot of pancakes to a lot of people in a relatively short period of time GLAMARAMA hires a specialized food service.  The one they hired this year had long griddles with an overhead depositor that moved the length of the griddle like a gantry crane.  It would precisely deposit the batter to make a row of 5″ pancakes.  The operator would then move it by hand and deposit the next row, repeating this as they moved along the griddle.  Another worker followed behind the depositor with a pancake turner (flapjack flipper) and turned the pancakes when they were done on the first side.  Although hand labor was still involved it was an efficient, high volume, production process that did not require an army of volunteers.

When we were done drinking coffee and chatting Linda headed back to our motorcoach to prepare food for our family gathering on Sunday afternoon.  I headed over to the seminar building for a presentation by Jason and Nikki Wynn of Gone with the Wynn’s.  They were joined by Chris Dunphy and Cherie Ve Ard of Technomadia and did a panel discussion on earning income on the road.  They also covered work-camping and volunteering in exchange for a camp site.  They did an excellent job, relaxed and low key, and streamed the event live to the web.  The logins indicated that 68 people viewed the presentation online, which was probably more people than were in the room.

Geeks on Tour got their flash drives in (Nick and Terry Russell brought them down from Elkhart).  I wanted to restart our subscription, but wanted the flash drive instead of the CD as Linda needed it to store some files.  I ended up with both.  Their Tutorial Video series ( http://geeksontour.tv ) is an amazing resource for learning how to use a wide range of technologies for Planning, Preserving, and Sharing you RV adventures.

At 10:45 AM I met with Jerry Yates, Executive Director of FMCA, in my role as a member of the national education committee, to talk about RVillage.  It also gave me a chance to further explore making online education available to FMCA members, such as that provided by the Geeks On Tour, either directly from the FMCA website or through discounted subscriptions to provider websites.

Linda helped Alma Baker get situated for the Fleetwood hot dog lunch and had a tomato and onion sandwich while she was there.  I had a couple of tofu hot dogs in our coach and eventually headed over to a 1:30 PM seminar on 120 VAC by Gary Bunzer.  It was very good, as usual, but by Saturday afternoon seminar attendance had thinned.  This was a repeat of a session he had done on Wednesday, so many attendees who wanted to see probably already had.

Linda hung around the coach waiting for Butch and Fonda, who drove over from Twelve Mile, Indiana to work with her on some aspects of their pending business sale.  I came back to the rig to say hello and around 4:45 PM we gathered up some hummus, chips, and beverages and headed over to the 5:00 PM RVillage get-together.  The volunteer dinner started at 4:30 PM, but we decided not to go as we knew there would be little-to-nothing we would be able to eat.

Nikki Wynn had scheduled the RVillage get-together in the Dog and Cat Pavilion and we ended up with a nice turnout of 17 people.  It was not a pot luck, but enough folks brought munchies and extra beverages that everyone had something.  We milled around conversing in shifting groups and eventually formed chairs into a (sort of) circle.  Chris Guld suggested we go around and introduce ourselves and say where we were when we were 15 years old and whether we had any notion that we would find ourselves where we are now.  It turned out to be a fun, low key, way to get to know each other by filing in a few personal details.

We disbanded by 6:30 PM, went back to our coach for a few minutes, and then headed over to the final evening’s entertainment.  The Walker Family hails from Nashville and we saw them a few years ago at the G.L.A.S.S. rally in Berrien Springs, Michigan.  Dad, mom, and seven kids; four girls and three boys.  The “girls” are now young women; two are married and one just had her first child.  They perform as “The Redhead Express.”  The boys are now 15, 13, and 11.  The older two play drums for their sisters and perform as a trio with guitar backup from one of their sisters.  Mom and dad joined the sisters for a couple of numbers, but the entire family never performed together.  My recollection was that they had the last time we saw them, but that’s been at least four years, maybe five, and Linda disagrees with my memory.  Regardless, they are very talented and put on a spirited show of country songs with a bit of gospel and patriotic stuff mixed in; just what you would expect from a Nashville-based group.  They did not, however, use any pre-recorded sound tracks.

Following the concert there were drawings for prizes and the 50/50 raffle.  The Grand Prize was a gift certificate for an 11-day Adventure Tours Mega-Rally worth $3,000 (one motorhome with two people).  One of our GLCC members won $200 in the raffle.  Those of us “camped” in the GLCC area gathered by our rigs after the drawings and stood around talking until it cooled of to the point that everyone was ready to retreat into their rigs for the evening.

 

2014/06/13 (F) Day 3 Shop-Learn-Eat

Day 3 of the 2014 GLAMARAMA kicked off with coffee and doughnuts at 7:30 AM.  Those attendees going on the morning tour of the Jayco factory had to assemble early.  We had coffee and visited with friends until the vendors opened at 9:00 AM.

At the 2013 GLAMARAMA last September I had decided to buy a small video camera/recorder to mount on the inside of the windshield and record what is happening in front of the coach.  By the time I went to buy it on the last day at 3:00 PM the vendors were closed.  I did not make the same mistake this time and bought one this morning.  We still need to get a 32 GB high speed SD card to go with it.

We had spotted some Velcro straps at another vendor and decided to buy a pair to use for securing the Pressure Pro TPMS repeater to the inside rear view mirror in our Honda Element.  The same vendor had an LED light that looked like it might fit in our downlights.  They loaned us one to try.  It fit well and the light was OK.  I returned the sample and bought a new one.  Lloyd De Gerald had his Aqua-Hot service booth right next to the Aqua-Hot factory booth and I purchased an inline secondary fuel filter from him.

Michele Henry from Phoenix Paint ordered some silver (white) reflective tape for us as it was on sale and we thought it might look OK around the lower portion of our bus.  (There is a channel on all of the lower body panels, as well as the front and rear bumpers, where this reflective tape is intended to go.)  Our hope was that the tape would reflect the adjacent paint color while making the bus much more visible at night.  Alas, it did not pick up the surrounding color and the tape was a little wider than the channel, which would complicate the installation.  I did not see it, but Linda did, and did not like the way it looked.

Josh Leach specializes in interior projects and is currently working out the Phoenix Paint facility.  He teamed up with Darin Hathaway (the Aqua-Hot technician who serviced our Aqua-Hot system on Monday) and Michele Henry (who painted our coach two years ago) to get a booth at the GLAMARAMA.  We discussed our interior remodeling ideas and agreed to have him come by the coach to see it.

Just after noon Linda drove to the Whole Foods store in Mishawaka, Indiana to get ingredients for dishes she planned to serve back at the house on Sunday.  I attended two seminars, both by Gary Bunzer (the RV Doctor).  The first one was on balanced battery systems.  The key concept of that seminar was that there are poor, OK, and optimal was to interconnect multiple batteries to form a battery bank of the required voltage and energy storage capacity (Amp-Hours).  The second seminar was on controlling/eliminating holding tank odors.  Linda dropped in on this one for a little while and then headed over to the reception for vendors and chapter officers.  I joined her at the reception after the seminar concluded.  Gary has published a column somewhere on RV maintenance and operation every month for the last 38 years.

The vendor and chapter officers reception was very nice, with fresh fruit and veggies, cheese and crackers, some deli meats, and a choice of wines.  We returned to our coach for a little while after the reception before heading over to the evening entertainment.  Keith Longbothum and his sidekick, an excellent harmonica player, put on a high energy show that was initially Nashville country but morphed into gospel and patriotic.  One thing I noticed about entertainment tonight and on Wednesday was the use of pre-recorded instrumental soundtracks which make it possible for a small ensemble to produce a very full sound without having to pay a lot of musicians.

There was a door prize drawing after the entertainment.  We did not win.  The head of the parking crew also gave instructions for departure on Sunday.

 

2014/06/12 (R) Rallying Day 2

First of all, yesterday was our daughter’s 33rd birthday.  Happy birthday, Meghan!

At most rallies “breakfast” consists of coffee and doughnuts, with a pancake and sausage meal thrown in somewhere.  We like our own coffee a lot better than what is typically served at rallies, but these breakfasts are included in our rally fee, so we go have coffee and sit and talk with folks.  Mostly it’s about sitting and talking with folks.  Larger rallies are social/educational events.  Smaller rallies tend to just be social events.

The GLAMARAMA organizers had arranged for a morning and afternoon tour of a local Dometic factory today, with tours of a local Jayco factory tomorrow.  Slots were limited, requiring an advance reservation, and a single school bus was contracted to transport each group.  We did not go, but our GLCC friends who did said it was an excellent tour of a very impressive factory.

We went through the vendor buildings when they opened at 9:00 AM and took stock of who was there and what they were selling.  We usually check out the vendors early in the rally but do not buy anything right away, giving us time to ponder possible purchases.

We did not attend any seminars today.  Most of the chapter socials were scheduled to start at 4:00 PM including our Great Lakes Converted Coaches meeting.  Linda and I were responsible for the food, most of which we had ordered from Pizza Hut on Tuesday.  At 2:15 PM we drove to the Kroger on the northwest side of Goshen to get ice, bottled water, and diet Coke.  (Pizza Hut is part of PepsiCo, so they only sell Pepsi soda products.  I do not care for Pepsi and usually forego a soda beverage if Pepsi is the only thing available.)  The food was supposed to be delivered to Gate 5 of the Fairgrounds at 3:35 PM but the driver was delayed by trains blocking his route.  (This is common in Goshen.)  He finally arrived at 3:50 PM.  We transferred all of the food to our car, paid him, and headed for the pavilion.  A few people had already arrived and they helped us unload the food and set it up on two tables.  By the time we had it ready to serve most folks had arrived and most of them were hungry.  We did not take a head count but I estimated 35 people, plus or minus.  Once everyone had a chance to eat we had a short business meeting.  By the time we were done and had everything cleaned up it was 6:30 PM.  We went back to our GLCC parking area and visited a little longer with our immediate neighbors before retire to our buses for the evening.  On the day of the chapter socials there is no evening entertainment; those who want to usually gather for cards or bingo.

 

2014/06/11 (W) GLAMARAMA14 Day 1

Although the opening ceremonies for the 2014 Great Lakes Area Motorcoach Association (GLAMA) area rally (GLAMARAMA14) took place at 7:30 PM, the Elkhart County 4-H Fairgrounds were busy with activity all day.  The golf cart shuttles started running at 7:30 AM and the parking crew members were at their stations and started parking motorhomes at 8:00 AM.  The registration building was open at 8:00 AM, the indoor vendors were open at 9:00 AM, and the food vendors were open at 10 AM.

The Fleetwood Motorhome Association (FMA) had rolled their rally into the GLAMARAMA, and as part of their participation they sponsored Gary Bunzer, the RV Doctor, as the featured speaker.  Gary normally only does national rallies and GLAMARAMA14 was the first time he had agreed to speak at an FMCA area rally.  He was scheduled for a full set of presentations starting at 1:30 PM today.  There were no other seminars at that time and he drew a large crowd, as he usually does.  He had a second seminar starting at 3:30 PM but we could not attend as we were scheduled to drive golf carts from 4:00 – 6:30 PM.  Fortunately he is repeating that seminar on Saturday.

Sometime during the last day or so I received a draft copy of the June 2014 Bus Conversion Magazine for review of my cover/centerfold article on the Cool Cruiser; a GM PD4106 I photographed at the 2014 Arcadia Bus Rally in late December.  I sent back a few minor corrections.  The editor had some health issues that delayed the May issue and they are working very hard to get the caught up so I got my comments back to the ASAP.

We had received an e-mail a week or so ago regarding the RVillage Ambassador Program and had responded that we were definitely interested in participating.  Earlier this week we were notified that a webinar was scheduled for Saturday May 14 at noon.  I e-mailed back that we could not participate in the webinar at that date/time due to GLAMARAMA activities.

At 4:00 PM we picked up our golf carts and headed out for two and a half hours of fun driving around the fairgrounds meeting people and providing rides and/or directions.  There had been a threat of rain all day but it held off until after our shift ended.

The evening entertainment was provided by New Odyssey, an extremely high-energy three-man group out of Chicago, Illinois that plays 30 different instruments.  They put on a great, but slightly familiar, show and we finally figured out that we had seen them a few years ago at a G.L.A.S.S. rally in Berrien Springs, Michigan.  (Great Lakes Area Spring Spree.)

Before the show ever started the skies opened up and it rained very hard.  We had left the roof vents/fans open/on, with a running computer sitting directly under one of them, so I ran back to the coach to close everything up.  It was a short distance, but I was soaked by the time I went 10 feet.  Ironically, but luckily, not a single drop of rain had entered the coach, perhaps because we were parked under a very large tree.  Still, I closed everything, dried off and changed into my rain gear for the walk back to the assembly hall.

 

2014/06/09 (M) Mobile Service

One of the interesting things about RVing is the availability of mobile service providers.  The mechanic who maintains our bus chassis, Joe Cannarozzi, travels all over the U. S. from his base in Chicago, Illinois.  Other vendors, many full time RVers themselves, travel the RV rally circuit providing on-site service.  We stopped by Phoenix Paint late in the morning to visit with Michele Henry, who painted our motorcoach in 2011/12, and met Darin Hathaway there.  Darin is an independent Elkhart-based factory trained/authorized Aqua-Hot service technician.  Our Aqua-Hot has not been running well the last few of times we have tried to use it, even failing to ignite once and producing copious amounts of white smoke for as long as five minutes if/when it did.  I described the symptoms we’ve experienced and what we have done to try and diagnose the situation.  Darin had time in his afternoon schedule to service our unit so we arranged to have him come over to Elkhart Campground to do the work there.

Darin arrived around 2:15 PM and performed the standard annual maintenance / tune up.  He let me watch and ask questions and I learned a bit more about the unit and how it functions.  He removed the burner and then removed the swirl chamber which had a buildup of carbon soot.  He removed the nozzle, flame sensor (photo eye), igniter electrodes, and the photo (mounting) disk.  He also noticed a small inline final fuel filter that needed to be replaced.  He clamped off the lines, removed it, and installed a new one.  I wanted a spare, but he only had the one with him so he said he would order one for me.

He disconnected the two main electrical harnesses, plugged in his service control box, and then installed a pressure gauge into the nozzle port.  He activated the fuel pump and the fuel pressure was just over 160 PSI.  It was supposed to be 145 PSI so he showed me the adjustment screw and backed it down to the proper level.

The photo disk was slightly wrapped which is not unusual, but could prevent it from sealing the combustion chamber, so he installed a new one showing me how to make sure it was loose enough that it could position itself correctly when the main blower/pump housing was re-installed.  I got a second disk to keep as a spare.  He installed a new nozzle and then reinstalled the two igniter electrodes and showed me how to set the spark gap.  He also pointed out that the cable clamp on top of the main blower/pump housing is the spark gap tool.  Nice touch.  He said the old nozzle was a bit loose which might have allowed a little fuel to get into the combustion chamber without going through the nozzle.  His tips for nozzle installation were to always use two wrenches and to tighten the nozzle, back it off, and tighten it a second time.  Apparently this helps the threads seat and seal.

He checked the four rubber grommets around the housing and said they were still in good shape and probably relatively new.  I got four for spares, two lefts and two rights.  I might as well get parts while I can.  He cleaned up the swirl chamber and re-installed it, seam side up.  Very important.  He checked the spark igniter and it worked and then failed.  He spent some extra time that was not part of the routine service diagnosing and fixing this issue.  He thought it might be a marginal or failed coil, but after tightening the wire connections and flexing the wires a bit, it seemed to work fine with repeated testing.  The coils are relatively expensive and decided not order one as a spare at this time.  Hopefully I don’t regret that decision somewhere done the road.

With critical components replaced, and everything cleaned and adjusted, Darin inspected the main combustion chamber for signs of fuel or coolant leakage but did not see anything out of the ordinary.  He secured the main blower/pump housing to the combustion chamber / “boiler” assembly using a short quarter-inch socket ratchet with a 12″ extension and suggested that I do the same.  Apparently it is very easy to over-torque these bolts and break the mounting tabs, which is a very bad thing to do.  A final test resulted in the unit starting up immediately with clean exhaust; no smoke, black or white.

We spent a few more minutes trying to determine which thermostats in the house (there are three) controlled which of the three circulating pumps, but did not figure it out.  The is important because the radiator for the water bay (where the Aqua-Hot is installed) is clearly part of one of the coolant circulation loops controlled by one of the thermostats in the house (the leftmost of the three at the top).  The radiator for the front bay is also part of one of the house loops but I do not know if it is tied in with the water bay radiator or with a different zone.  Darin said there was usually a separate thermostatically controlled zone for the bays, but I assured him that our coach was not configured that way.  Our unit does have a forth circulation pump that is tied in with the main engine coolant.  It can be used to pre-heat the engine or to provide heat from the engine to the coach.  Darin indicated that anytime the burner is lit one of the circulation pumps will be running, usually the middle one.  In our unit it seemed to be the engine pre-heat pump, but I later discovered that I had the pump turned on.

It was after 3:30 PM by the time Darin was finished and I had a 4:00 PM conference call meeting of the FMCA national education committee.  We turned the diesel burner on from its normal control switch and let it run for one complete cycle while he finished up the paperwork.  As the cycle finished I saw a little white smoke in the bay, which was still open.  I opened the door to the small compartment underneath the Aqua-Hot and it was full of white smoke.  I have the battery for the fuel polishing module installed in there but the compartment us otherwise empty save for a large diameter tube (5″?) that runs from the bottom of the Aqua-Hot through the compartment, and out the floor.  This tube provides fresh air to the combustion chamber and also provides a conduit for the exhaust pipe.  There was obviously a double problem:  1) exhaust gas was leaking from the exhaust pipe somewhere, and 2) the large outer tube was not sealed.  Add that to the project list.

I called in to the FMCA national education committee meeting at 4:00 PM and by 4:10 PM (EDT) we had enough members for a quorum.  Committee chair Gaye Young worked us through the agenda and we were done with our first meeting an hour after we started.  The committee is charged with looking at four topics, one of which is RVillage.

We had a quiet evening and had pan-grilled tofu with caramelized onions and bar-b-que sauce for dinner, followed by a final stroll around the campground.  We got online with the campground WiFi via our WiFi Ranger and took care of e-mail, RVillage, and WordPress tasks before turning in for the evening.

 

2014/06/08 (N) Positioning

We were up around 7:00 AM, showered, dressed, and gathered up toiletries and other last minute items for our outing.  I did a last minute check of e-mail and RVillage and then shut down the computers, printers, and NAS units and packed up my laptop.  We started our final loading process at 9:00 AM and had everything on board by 9:20 AM.  While Linda configured the car for towing, I turned the chassis batteries on, disconnected the shorepower line, stowed the cord, checked that the inverter was operating, and opened the air valves for the engine accessories and the air line to the car auxiliary braking system.  While Linda closed up the utility bay I fired up the main engine and drained the moisture out of the auxiliary air tank.  We checked the lights and finally checked that all of the bays were closed and locked.  GPS and TPMS on with all tires reporting in, all gauges reading normal, and side mirrors adjusted.  Tag axle up for the tight 180 degree turn exiting the driveway and all ahead slow while Linda verified the car wheels were turning.  She was on board and buckled in at 9:30 AM and we were on our way.  We have gotten reasonably efficient at this departure routine, but when driving a bus with a car in tow you do not simply turn the key and drive away.

We had light rain overnight and it was still drizzling as we pulled out.  No problem; cloudy skies often make for easier travel.  We drove up to M-59 and headed west, picking up I-96 westbound on the west edge of Howell.  By the time we turned onto I-69 southbound at the southwest corner of Lansing, Michigan we had run out from under the rain and the overcast gave way to partly cloudy skies with patches of blue making for very pleasant driving conditions.  At Coldwater, Michigan we headed west on US-12, a route we have driven many times and always enjoy.  Just north of Elkhart, Indiana we exited US-12 onto M-205 which swings south and becomes SR-19 as it crosses into Indiana.  About two miles into Indiana we turned east on County Road 4 and 0.7 miles later turned into the entrance to Elkhart Campground.  It was a little before 1:00 PM and we had made the 160 mile trip without rest or fuel stops.  I set the cruise control at 60 MPH on the Interstates and 55 MPH on M-59 and US-12, but had to slow down for interchanges and lower posted speed limits going through small towns.  We usually base our expected travel time on an average speed of 50 MPH which seems to account surprisingly well for all of these variations.

We got checked in to the Elkhart Campground using our Escapees membership to save 15% off of their overpriced 50A FHU grass sites.  They put us in a new part of the campground we have not used before.  The spot was level so I but the tranny in neutral, set the parking brake, and shut the engine off.  I shut off the air and chassis batteries and hookup up the shorepower line while Linda got the inside ready to use, our standard arrival routine.  In all fairness, Elkhart Campground is not a fancy RV resort but is nice enough, and one of only two RV parks in Elkhart, Indiana, so part of what you pay for here is location.  We have been here at least 9 times, usually for Great Lakes Converted Coaches rallies.  It is centrally located for much of our membership and has a building with meeting rooms and kitchen facilities that they let us use for no additional charge.  Our reason for being here now is to add a couple of days of RV use to the GLAMARAMA rally and position ourselves for an easy, early morning entry into the Elkhart County 4-H Fairgrounds on Tuesday.

For lunch Linda served some of the cold three bean salad she made yesterday along with tofu hotdogs (with mustard, relish, and onions, of course).  After lunch we got our WiFi Ranger connected to the campground WiFi network and checked in to the campground on RVillage.  The website indicated that there were 11 other people checked in here, but we knew that some of them had been here after the recent SKP Escapade and subsequently left.  We went for a walk around the campground and found the FMCA Frustrated Maestros (Great Lakes Chapter) camped by the activities building.  It was obvious that they were having a pre-rally and using it to rehearse before heading to the GLAMARAMA rally in Goshen on Tuesday.  We recognized Ron and Meredith Walker’s Prevost XL bus conversion but did not see them outside.

As we were finishing our walk we ran into Nick Russell of The Gypsy Journal and he invited us in to their motorhome for a brief chat.  Terry was busy removing their old combo washer/dryer to make room for the new one they are supposed to get tomorrow, but she put her work aside to visit.  We finally got to see her loom which we have read about on Nick’s blog.  Considering what a sophisticated device it is, it fits surprisingly well in their Winnebago Ultimate Advantage (which has slides).  Terry was obviously very excited to have it and enjoyed describing its operation to us.  She is mostly self-taught and already producing some very intricate designs.

For dinner Linda made a nice green salad to go along side a bowl of the vegetable chili she made yesterday, served with crackers and a glass of Franzia Sweet Red wine.  We went for a walk after dinner and ended up having a conversation with several of the Frustrated Maestros, including Ted (K0DDB) who took up the banjo at age 56.  As we walked past Nick and Terry’s motorhome Terry was outside talking to Greg and Jan White.  Greg was “parting out” the combo washer/dryer that Terry had just removed from their rig to salvage as many usable spare parts as possible since they have the same model in their American Eagle coach.

We got back to our motorcoach just before 8:00 PM and tried to connect to the Technomadia live UStream videocast they were doing for the Mobile Internet Aficionados private membership Facebook group, but the WiFi at Elkhart Campground was not up to the task and I did not feel like turning on our Verizon MiFi device.  Linda turned the TV on instead and checked out the stations available to us.  We had all of the major networks and decided to watch the final episode of Cosmos and then turned in for the night.

 

20140418 (N) Taxi Turn Oops

We complied with the Fairgrounds’ request that we not depart until today, but we wanted to be on the road by 9 AM.  We were up at 7:30 AM and got busy right away with our departure routine.  The 5th Wheel parked next to us decided to leave last night.  They were from Alaska and the husband was an instructor for the RV Driving School.  He had also been an “ice road trucker” at one time.  I told him that I was not sure what the best technique was for exiting the infield over soft ground with freshly spread loose gravel.  He suggested the following technique: 1) Pull up the tag axles to put more weight on the drive tires and to keep them from dragging on the ridges created by the space between the drive tires; 2) transmission in 1st gear (manual selection); 3) Keep the engine at 900 – 1,100 RPM (high-idle) and avoid quick changes in engine RPM to keep from spinning the drive tires; 4) keep moving; don’t stop.

We were ready to go by 8:00 AM and said our farewells to Butch and Fonda.  We were anxious to get home and decided not to stop at the dump stations.  Linda went ahead of me in the car to block any traffic from entering the infield through the gate.  I made it through the soft part of the infield just fine using the technique as previously described.  I got across the horse track without difficulty and then made a sharp turn onto an interior road where we could stop to hook up the car.  As I came around the corner I clipped a sign with the driver side rear view mirror.  In my defense I thought it was a cloth banner, but it wasn’t.  The mirror was pulled loose from the motorized base and plastic parts were broken in the process.  Butch and Fonda were pulling out behind us and stopped to see what the problem was.  We used some of the Rescue Tape we keep on board to tape the mirror onto the base and adjusted it by hand as best we could.  I had an adequate view down the driver’s side of the coach, allowing me to drive it safely.  We hooked up the car and were on our way by 9:00 AM.

The rest of the trip was smooth sailing and without incident.  We exited the fairgrounds onto Monroe Street east to County 29 north to IN-4 east to IN-13 north to US-20 east to I-69 north to I-96 east to MI-59 east to Hacker Rd south to our house.  We had light traffic and pleasant weather for the whole drive.  When we pulled up in front of our house (on the street) Linda got out to help position the coach in the driveway.  Jasper immediately came out from under the passenger seat and got down in the stairwell to look out the lower window and I had the sense that he recognized we were home.  As soon as we got parked, Linda took the cats inside and then took off for the grocery store while I plugged in the shore power, unhooked the car, and started unloading the bus.

I spent a little time getting a couple of blog posts uploaded to WordPress before John and Diane arrived around 5:00 PM.  Linda made a very nice green salad with walnuts and dried cranberries and a bow-tie pasta dish with sun-dried tomatoes, mushrooms, garlic, and pesto for dinner.  John and Diane brought a bottle of Barefoot Sweet Red wine which we had with the meal.  We had fresh mixed berries with biscotti cookies for dessert.  Tomorrow was a work day for everyone but me, so John and Diane took their leave around 8:30 PM and Linda headed off to bed shortly thereafter.  Since I did not have to get up at Oh-Dark-Thirty I worked at my desk for a while before retiring for the night.  Linda has not been feeling well for the last few days and cannot figure out if she has a cold or allergies or both.  I’ve been tired too, but rallies can do that, especially when we are working.

 

2014/05/17 (S) Working While We Wait

As soon as the fairgrounds and Escapade management had asked those of us parked on the horse track infield to delay our departure until Sunday (with a free night’s stay Saturday evening) we decided to comply with their request.  Our friends, Butch and Fonda, are parked next to us and also decided to delay their departure.  Butch and I hung out this morning while Linda worked with Fonda on their business accounting.

Butch and I were not having any luck solving all of the world’s problems so we decided to investigate our Aqua-Hot problem.  The expansion reservoir had apparently overflowed again so I cleaned up the coolant as best I could.  I turned on our Aqua-Hot so Butch could observe the smoke on startup and try to detect if it had an odor associated with it.  The unit startup up on the first try and produced a lot of white smoke.  The white smoke eventually disappeared, but it took quite a while.  Neither of us detected the slightly sweet smell of combusted coolant.

I had hoped to have a definitive analysis of our Aqua-Hot situation, but I ended up with data that was inconclusive, at best, and inconsistent, at worst.  Recent experiences with a failure to start, excessive white smoke on startup, needing to add coolant, and failure to hold pressure all suggested a coolant leak, possibly into the combustion chamber.   On the other hand, it started fine today and the white smoke did eventually clear up.  There were alternative explanations for some of the data and these always need to be considered.  Jumping to conclusions about what is wrong with a bus/conversion can be unnecessarily expensive.

The loss of pressure may have been due to our inability to keep the pressure tube vertical because of the tight quarters.  The pressure is released by pushing this tube to the side where it connects to the radiator fill spout.  The loss of coolant could be due to the undersized expansion reservoir overflowing when the unit heats up.  I know for a fact that it does this if I have too much coolant in the reservoir when the unit is cold.  To pin down whether or not there is a coolant leak into the combustion chamber I will have to remove the burner assembly from the combustion chamber, pressurize the closed coolant system, and visually check for leaks.  Even if I don’t find a leak there that will not rule out a leak somewhere.  Ugh.  Aqua-Hot units are expensive to replace and the model we have is not longer made, so our only direct replacement option is a rebuilt unit.  The unit in the coach is a rebuilt one that was installed sometime between Sep 2009 and April 2010.

We quit working with the Aqua-Hot around 1:00 PM to have lunch before heading over to the Tri-Chapter Rally (TCR).  A little before 2:00 PM we drove over to the AG Hall for the opening of the TCR.  The TCR is an annual joint event of SKP Chapters 6 (Michigan – Great Lakes), 36 (Ohio – Erie Shores), and 51 (Indiana – Hoosier Neighbor).  The TCR is usually held in late June on the same weekend as the ARRL Field Day ham radio operating event so we have never been able to attend.  Because Escapade was in Goshen, Indiana the TCR was scheduled at the same fairgrounds immediately following the national rally.

We are members of Chapter 6 and Butch/Fonda are members of Chapter 51 but neither of us registered for the TCR because we had planned on leaving today.  Since we were “stuck” here we figured we would make an appearance at the 2 PM opening of the rally and play it by ear from there.  It turned out that 2:00 PM was the beginning of registration; the opening social was scheduled for 4:00 PM with dinner at 5:30 PM.  The rally organizer said we could come to the social without registering, but wanted us to pay if we were staying for dinner.  That seemed reasonable and we indicated that we would return at 4:00 PM to be sociable for an hour.

We never made it back.  By the time 4 o’clock came around we were all tired and none of us felt like being sociable.  We eventually got hungry and went to the South Side Soda Shop (SSSS).  SSSS was featured in an episode of Diners, Drive-ins, and Dives (Triple-D).  It was appropriately quaint, the wait staff was very friendly, and the food was good and plentiful; exactly what you would expect from a place featured on Triple-D.  Linda and I had garden salads with a dressing we had never had before; oil and capers.  It was delicious; a new favorite.  We split a veggie sandwich, flat bread with pesto and hummus, and an order of curly fries.  The fries alone would have been a meal!

Butch bought a WiFi Ranger Mobile and Go2 combo at the Escapade.  Earlier in the day he attached the Mobile unit to a couple of pieces of PVC pipe which he used as a mast by securing them to the driver’s side mirror on their bus.  He ran the coax in through a window and hooked it all together.  After dinner I worked with him to get the WFR Mobile/Go2 configured while Fonda visited with Linda.

I have done a couple of posts this past week that brought up concepts from aviation because I used to fly airplanes and thought there were interesting analogies to be made.  Well, here’s another one:  RVing, much like flying, is weather dependent, and more so than you might realize.  We have had to be pulled out of two different fairgrounds at the conclusion of week-long rallies where we were parked on grass and it rained (hard) most of the week.  Unless you only stay at campgrounds with paved roads and sites this will eventually happen.  When threatening weather is in your path, you ground yourself; a high profile vehicle with an amateur driver does not belong on the road in high winds, blinding rain, or icy conditions any more than a private pilot should be in the air under those conditions.  An RV has no more business crossing a flooded road than a car or pedestrian does, and the reason you have a home that can be moved is so you can get it out of harm’s way; RVs are not designed to be driven into tornadic storms, hurricanes, or blizzards.

We really need to be on the road Sunday morning as we have company coming for dinner that evening, Linda has to go into the bakery on Monday and Tuesday, and someone is coming to the house on Wednesday to discuss our pole barn project.  But just because we need to leave doesn’t mean we will be able to.  That will be decided by Mother Nature.  If we cannot get the bus out on Sunday Linda will take the car and return home and I will return with the bus (and the casts) when I can.

 

2014/05/16 (F) Final Approach

The overnight low temperature hit 33 degrees F; probably not a record for this location and date, but still unseasonably cold.  There are plenty of attendees at this Escapade who are from more southern parts of the country, and they find this cold snap particularly unpleasant.  We brought a range of clothing options so we have been able to layer our garments as needed.

Today is the last day of the Escapade.  For many participants there is a feeling of things winding down.  The vendors closed up at 3 PM yesterday.  Some left last evening and others pulled out today.  There were morning seminars, but not as many.  People are tired after a long, busy week, and the dreary, cold, damp weather has caused some folks to huddle in their rigs.

SKP craft donations at Goshen Hospital.  Bard (standing center) and Vera (standing right).

SKP craft donations at Goshen Hospital. Barb (standing center) and Vera (standing right).

The experience is different for the Escapade staff that is busy bringing Escapade to a safe and successful conclusion and preparing for the post-rally tear down and wrap-up.  Even after you have landed a plane on a runway there is work to do taxiing back to the parking spot and tying it down.  There is a technique to taxiing a small plane, and if you don’t do it correctly an unexpected cross-wind can flip the plane over; so too with a big rally.  The muddy infield situation, for instance, has added work for them.  It’s always something.

This greyhound at the pet parade had a jockey!

This greyhound at the pet parade had a jockey!  Such a sweet dog.

The fairgrounds appears to have finished spreading gravel around the worst part of the infield along the makeshift route leading to the place where we all have to cross the horse track and exit through the gate in the track perimeter fence.  It still feels very soft under our car tires, so it remains to be seen whether the repairs will be adequate to get the 100 or so RVs that are parked here out of the infield over the course of Sunday, Monday, and Tuesday.  Our hope is that heavy vehicles driving on the gravel will pack it down.  Our fear is that the loose gravel will simply cause our drive tires to spin and our steer tires to plow.

I took pictures every dog in the parade, but these greyhounds really captured my attention.

I took pictures of every dog in the parade, but these greyhounds really captured my attention.

I drove over to the seminar building around 8:45 AM and Linda stayed in our rig.  I took a few shots of Lou’s photography seminar and then moved the car over by Lou and Val’s 5th Wheel.  (They are parked in a particularly convenient place with room for an extra car.)  I grabbed some coffee and joined Curtis (from RVillage) for a brief chat before walking over to the Escapade office at 10 AM to meet up with the ladies who were taking donated craft items to the local hospital.  Lou was going to be tied up following his morning seminar putting together the final slide show for the closing ceremonies at 3:00 PM and asked me to cover the hospital event as we wanted to include a photo in the final slide show and Kathy Carr, Escapees RV Club president, wanted them for future use.

This "Scotty" was dressed for the parade.

This “Scotty” was dressed for the parade.

When I got back I went to Lou’s trailer, I gave him the CF card from the hospital shoot and got back the CF card I had left with Val last night.  I photographed the Pet Parade at 11:15 AM and then joined Linda at the SKP Amateur Radio BOF brown bag lunch.  We stayed as long as we could and then headed next door to photograph the Chili Cookoff.  With that activity captured we returned to Lou and Val’s 5th Wheel, transferred the new photos, and got my CF cards back.  We then headed back to our coach.

It was cold and drizzly, so I guess this makes sense, at least for a small dog.

It was cold and drizzly, so I guess this makes sense, at least for a small dog.

Michele Henry of Phoenix Paint had called me while I was taking photos at the hospital to let me know she was on her way to the fairgrounds.  I texted her when we got back to our coach and a little while later she pulled up with her kids, Raven and River.  Both of the kids know me from the time I spent at Michelle’s shop working on my own projects while her crew prepped and painted our motorcoach a few years ago.  We had a nice visit and Michelle took a few minutes to look at our rear bumper fascia.  All too soon we had to head over to the closing ceremonies so they took their leave of us.

We had a Golden Retriever that lived to be almost 15 year old.  They will also be our favorite dog breed.

We had a Golden Retriever that lived to be almost 15 years old. They will always be our favorite dog breed.  So gentle and loving, everyone is their new best friend.

We wanted to get to the Assembly Hall early so we could see the slide show.  Once again, Lou used a good selection of photographs that I took and did a nice job of manipulating them to improve their appearance.  Just before the opening ceremonies we received our Escapade Volunteer Pins and two tickets for the volunteer prize drawing.  Lou and I met briefly with Bob Pinner to coordinate what needed to be photographed, who was going to do what, and from what perspective.  Following the closing ceremonies we photographed the grand prize winners and sponsors and then headed over to the Escapade office to photograph the Chili Cook-Off winner in her prize apron.  We went back to Lou’s trailer to transfer a final set of images and we were officially done photographing the 54th Escapade.

There were some post-closing activities, however, and we attended the Chapter 46 Lincolnland (Illinois) social at 4PM with Lou and Val, who are members.  A couple of other groups were also meeting at 4:30 PM.  At 7:00 PM Johnny Cockrum provided the music for a farewell dance/party.  Snacks were provided, BYOB, but we did not go.  The temperatures dropped as the sunlight faded and by the time we finished dinner we did not feel like going back out in the cold.  I had requests from a couple of people for photos and took care of those via e-mail and Dropbox before going to bed.

2014/05/15 (R) Base Leg

As a private pilot of a small airplane there is a standard way to approach an airport that does not have air traffic controllers directing the flow of aircraft to/from the runway(s) and surrounding air space.  That standard way is called “the pattern” and when landing one must enter and follow the pattern correctly.  The pattern will be clockwise (right hand turns) or counterclockwise (left hand turns) and involves segment called “legs.”  Standard radio frequencies may let you know which runway and pattern are currently in use.

The pattern is usually entered on the “downwind leg” which is parallel to the runway with the wind coming from behind (tailwind) as much as possible.  You generally enter this leg at a specified altitude above the runway elevation and then start to descend.  How far you need to be from the runway is partially determined by your airspeed, but when I flew I would typically be a quarter to a half mile away.  As you pass the end of the runway you continue descending on the downwind leg for another 1/4 to 1/2 mile and then turn 90 degrees towards the runway.

This was our way out of the Elkhart Co. 4-H Fairgrounds horse track infield.  Not gonna happen.

This was our way out of the Elkhart Co. 4-H Fairgrounds horse track infield. Not gonna happen.

As you complete the turn you are now traveling perpendicular to the centerline of the runway on what is known as the “base leg” where you continue to descend.  On the base leg you often have a crosswind trying to blow you sideways off of your intended path and have to correct for that.  As you approach the centerline of the runway you again turn 90 degrees towards the runway, timing your turn so that you are lined up with the centerline as you complete your turn.

You are now on “final approach” and descending at a rate that puts you very close to the ground as you cross the end of the runway.  On final approach you are flying into the wind as much as possible, causing your ground speed (motion with respect to the earth) to be slower than your airspeed (motion with respect to the air mass you are flying through).  This slower ground speed makes it easier to land, particularly on a short runway.  Once you are over the runway you cut the engine power, bleed off more airspeed, and put the wheels on the ground.

Lou Petkus, head Escapade photographer, at the SKP Photographers BOF "row" table with Linda.  My friend Kate designed the logo.

Lou Petkus, head Escapade photographer, at the SKP Photographers BOF “row” table with Linda. My friend Kate designed the logo.

Landing an airplane is a complex task but all of the things you need to do become second nature with enough practice.  You develop a “feel” for your aircraft and the ability to visually judge altitude, distance, and speed, or use instruments to know these things.

So what does that have to do with the Escapees RV Club Escapade?  Not much, except that I have always liked analogies and today was the “base leg” of the event.  Tomorrow we “turn on final” and land.  Saturday is when we taxi from the runway back to our hangar.  For other attendees it will be a “touch-and-go” in which the landing is immediately followed by the application of full power and the airplane is taken back into the air.  Perhaps it will go around in the pattern and land again or it may vector off in some direction on a cross country trip.  I could extend this analogy in other ways, but I’m not going to.

Linda at the SKP Ham BOF "row" table pretending to use the HF rig.  We had a special event call sign (W9E) but not a good location for antennas.

Linda at the SKP Ham BOF “row” table pretending to use the HF rig. We had a special event call sign (W9E) but not a good location for antennas.

It was cold and overcast with light rain this morning and the Escapade decided to stop running the golf carts into the infield where we are parked because they were getting stuck in the mud.  (Golf carts are not off road vehicles.)  That meant we had to walk through the mud and puddles (small lakes, really), drive our car, or stay put in our coach.  I checked-in to the 7:30 AM ham radio 2 meter net and then put on a pot of coffee.

We wanted to hear Nick Russell’s seminar at 10 AM so we drove over around 9:45.  We gave a lift to one of our fellow infield campers who was struggling through the bad conditions using a cane.  After Nick’s talk we were heading to the hospitality area when I got a call from Curtis Coleman, founder/CEO of RVillage, inviting us to his rig for a chat.  We spent an hour with him and Patty (village tart) and his dog, Augie, who was very cute and friendly.  The central focus of our conversation was FMCA and how to get the leadership to understand what RVillage is, and how an FMCA/RVillage relationship is a win-win situation.  I have been appointed to the FMCA National Education Committee, which is charged with examining this issue and making recommendations to the national executive committee and that is why Curtis and I have been trying to arrange a conversation for awhile.

Curtis had an online business meeting to attend so we made our exit and headed over to the Geeks On Tour seminar on The Cloud.  In many respects the “cloud” is just another name for the Internet, with a subtle but important distinction.  In the past our interaction with the Internet (World Wide Web) was conscious, intentional, explicit, and initiated/controlled by us.  We typed in web addresses and navigated websites.  With the Cloud, much of the interaction with the Internet has been moved into “apps” that automatically move our data around and make it accessible from multiple devices from anywhere in the world with an Internet connection.  Take a picture on your smartphone and it shows up on your laptop and tablet.  Click, click and it’s in your latest blog post which shows up in a subscriber’s aggregator/reader.  It’s not magic, but it seems like it at times.

L-2-R Cherie and Chris of Technomadia and Curtis, founder/CEO of RVillage.

L-2-R Cherie and Chris of Technomadia and Curtis, founder/CEO of RVillage.

We went back to our rig and Linda prepared fresh grapes to take to the RVillage social at 4:30 PM.  We had a good turn out with about 90 people in attendance.  Many of them were already RVillage members, but some were not.  Just prior to the social there were 39 RVillage “members” “checked-in” to the 54th Escapade, although some of them, like us, were couples.  Everyone brought a snack, hors d’oeuvres, or beverage to share.  We mingled for a while and then Curtis connected his computer to the projector and grabbed the microphone.  He spoke at length and his vision, enthusiasm, and passion for this project was obvious.  Even those of us who are active on RVillage learned something.

After the social we moved the car over by Lou and Val’s 5th Wheel, which is parked near the Assembly Hall.  We watched the slide show and were pleased to see that quite a few of our images had been used.  We did not win a door prize, and left before the Ham-O-Rama talent show began.  Lou was there so I did not need to stay and take pictures.  Since he was taking photos I gave Val the Compact Flash card from my camera so Lou could transfer the photos to his computer after the talent show.  We then returned to our rig.

As the sun sank low in the western sky I photographed the infield of the horse track where we are parked.  The fairground is placing large quantities of gravel to try and repair the rutted, muddy mess that has developed as a result of the rains this past week and vehicle traffic going in and out of the infield.  The fairgrounds and Escapade management worked out a deal whereby we have been asked not to move our rigs until Sunday in exchange for a free night’s stay Saturday night.  We have been towed out of two other fairgrounds in the past, and would rather not repeat that experience if it can be avoided, so we will be staying until Sunday.  We would like to get out then as we have company coming for dinner Sunday night, but if not we will stay until we can.

I worked with Butch via telephone to get them set up on RVillage.  Even though they are parked next to us, we were both comfortably situated in our own buses for the evening and did not want to go back outside.  The high temperature today was around 50 degrees F and dropped quickly as the sun set.  With a strong wind from the north the wind chill was even lower.

2014/05/14 (W) The Mid-Point

The Escapees RV Club Escapade started on Monday afternoon and ends on Friday afternoon, so the middle of the event is sometime Wednesday afternoon.  Many attendees arrived on Sunday and many others, including us, on Saturday.  Most of the event staff, and many of the volunteers, arrived before that so today probably did not feel like the mid-point of the event to them, even though it was.

Teresa Moore, SKP RV Club COO, and Geroge Maylaben, owner of the RV Driving School.

Teresa Moore, SKP RV Club COO, and Geroge Maylaben, owner of the RV Driving School.

Linda still wasn’t feeling 100% so we skipped breakfast and went to the hospitality building for some coffee.  We like our own coffee better, but this coffee was included in the price of admission.  We took a stroll through the Marketplace (vendor area), which is in the two buildings adjacent to the hospitality area, and picked up a new regen tube and end caps for our portable water softener from RV-Water-Treatment.  We stopped to visit with Nick and a Terry Russell and renewed our Gypsy Journal subscription for two years.  As much as I love to read TGJ on newsprint, we switched our subscription to digital.  Printed materials are just more difficult to deal with in a mobile lifestyle.  Along with other informational and transactional activities we are trying to make our lives as paperless and mobile friendly as possible.

Our photo work continued even as the rains returned and intensified.  We tried to drop in on every seminar and the crafters to get photos.  Today was the Ladies Tea & Social, and some of the Ladies wore their Red Hats.  We attended the Ham Radio seminar, put on by Tom Abernathy (W3TOM), and Nick Russell’s seminar on Boondocking and off-the-grid RVing.  I got a few photos of the Ham-O-Rama (talent show) dress rehearsal while Linda went back to our coach to get some things.  As busy as we are, we always take time to smell the flowers and admire their beauty.

Some of the plants at Elkhart Co. 4-H Fairgrounds.

Some of the plants at Elkhart Co. 4-H Fairgrounds.

We met back at the seminar building for the Chapter 6 (Great Lakes) social.  We’ve been members of Chapter 6 for four years, having joined at the 2010 Escapade in Goshen, but to-date we have not managed to attend a Chapter 6 rally.  We may have met with other Chapter 6 members at a small social at the 53rd Escapade in Gillette, Wyoming last summer but today’s social was the first time we recalled meeting a larger group of members.  The Chapter will celebrate its 30th anniversary in September and we are planning to attend the rally if at all possible.  At the conclusion of our social I took a few pictures of the SKP Geocache BOF leaders in front of their BOF banner.  They asked if I would be willing to share the photos and gave me their contact information.

No entertainment was scheduled for this evening, leaving Escapade attendees free to socialize, go to dinner, or play cards or bingo in one of the two rooms designated for those purposes.  I photographed the bingo and then went to Lou and Val’s 5th Wheel so Lou could transfer my camera photos, and Linda’s cell phone photos, to his computer.  A few of the images will be used in an upcoming Escapade slide show and subsequently by the Escapees RV Club for other purposes.

Rally "bling."

Rally “bling.”

I had planned to work with Butch on some things this evening but by the time I got back to our coach it was an hour later than I had expected.  I chatted with him and Fonda for a half hour and then retired to our rig for the evening.  Nick Russell had asked if I would send him some of my photos (of him).  I went through all of the photos I had taken thus far and found the ones that included him and/or Terry.  I resized them to a maximum dimension of 1936 pixels (from 3872 for the hi-res JPEGs that come out if the camera), reducing each file to 25% of its original size, put them in a Dropbox folder, and e-mailed him the link.  I did the same thing for the SKP Geocache BOF photos.  By the time I checked and replied to e-mails and logged in to RVillage it was way past bedtime.

2014/05/13 (T) A Full Day

The Escapees RV Club Escapade started yesterday afternoon and ends on Friday afternoon, so Wednesday evening is the middle of the event.  Many attendees arrived on Sunday, and many others, including us, on Saturday.  Most of the event staff, and many of the volunteers, arrived even before that so today probably felt like we were well into the event even though it just started yesterday.

Curtis Coleman, RVillage Founder and CEO.

Curtis Coleman, RVillage Founder and CEO.

Yesterday we crossed paths briefly with Curtis Coleman, the founder and CEO of RVillage, at one of the seminars.  Although I had communicated with him in the past via RVillage messaging, e-mail, and telephone, it was the first time we had met in person.  We were all on our way to somewhere else and agreed to meet up at the Paul Evert’s RV Country social at 4:00 PM.

Linda and I continued our work as volunteer event photographers while also trying to attend a couple of seminars that interested us.  Kelly Hogan, founder/president of WiFi Ranger, gave an excellent talk on mobile connectivity.  Chris and Jim Guld, better known as the Geeks On Tour, did a nice overview of technology tools for travelers.

 

Chris and Jim Guld, the Geeks On Tour, presenting a seminar.

Chris and Jim Guld, the Geeks On Tour, presenting a seminar.

We take a stroll through the vendor area and ordered a new regen tube and end caps for our portable water softener.  We bought the softener from A-1 Water Treatment of Michigan at one of the RV rallies in Gillette, Wyoming last summer.  The owner sold A-1 but retained the portable RV softener business and now operates as RV-Water-Treatment.

Nick and Terry Russell of the Gypsy Journal in the vendor booth.

Nick and Terry Russell of the Gypsy Journal in the vendor booth.

We had hoped to meet up with Curtis at the Paul Evert’s RV Country social at 4:00 PM, but we had to leave for the Photography BOF social before he arrived.  BOF stands for “Birds Of a Feather,” the name the Escapees RV Club uses for special interest groups.  BOFs are distinct from Chapters which are geographic in scope.  We had a dozen folks show up for the Photography social.  Most of us had never met, so we spent some time sharing our photography background and interests. By the time the social ended the weather had turned.

The gathering storm.  It's been strange weather lately.

The gathering storm. It’s been strange weather lately.

Dinner?  What’s that?  We went early to the evening entertainment to see the slide show Lou had put together from our previous day’s effort.  Once again we failed to win a door prize.  The Homestead Pickers, a bluegrass trio, gave an excellent, high energy performance.  Linda wasn’t feeling quite right and left early.  I stopped at Lou and Val’s 5th Wheel after the concert so Lou could transfer my photos from today to his computer for inclusion in an upcoming slide show.  It doesn’t sound like much, but it was a long, full day.

The Homestead PIckers in concert.

The Homestead PIckers in concert.

 

2014/05/11 (N) A Pre-Game Show

Linda received Mother’s Day wishes this morning from our daughter and son.  Modern communications technology has certainly changed the RV experience, making it possible to stay in contact with family and friends, and even work or conduct business from the road.  The Elkhart County 4-H Fairground has WiFi and the WiFi Ranger Company is sponsoring WiFi connectivity and the WiFi Cafe during Escapade.  Our friends were having difficulty staying connected from inside their metal hulled bus, but we found and locked onto a strong signal using our WiFi Ranger Mobile Ti and shared it with them.

Panorama of the Elkhart County 4-H Fairgrounds.

Panorama of the Elkhart County 4-H Fairgrounds.

Today was still early arrival–the Escapade doesn’t officially start until tomorrow–but many rigs were already here and more arrived during the day.  For a rally that had not yet started there was a lot of activity.  Escapees runs a very popular “RVers Boot Camp” as a pre-rally before every Escapade.  They also have their SmartWeigh program set up to weigh vehicles.  The Geeks On Tour (Jim and Chris Guld) were also running pre-rally workshops on technologies for travelers, including Windows 8, cell phones, Picasa, and blogging.  Yesterday and today were big setup days for the vendors and Escapade volunteers were busy setting up the registration area, seminar rooms, and other venues.

I got a call from Lou Petkus (K9LU) regarding photography during the Escapade.  Linda and I had previously volunteered to be part of an official SKP Photographers BOF Escapade photography team.  He picked us up in a golf cart around 9:00 AM and we drove back to Building A to meet up with Sue Spahn, the forth member of our team.  Since the advent of digital photography, Escapade has featured a slide show of the previous day’s events just ahead of the evening announcements, door prizes, and entertainment.  Kathy Carr, Escapees RV Club president, and her daughter-in-law, Angie Carr, have handled this in the past, but asked the SKP Photographers BOF if they would take responsibility for it this year.  It was fortuitous that the BOF agreed to do this as Kathy and Bud had to return to Texas for medical reasons.  Kay Peterson, SKP founder and SKP #1, returned to Texas with them.

Molly Pinner (Escapade Director) and Lou Petkus (head photographer).

Molly Pinner (Escapade Director) and Lou Petkus (head photographer).

The photography team met for about an hour, looked at the schedule of events for the week, and discussed the kind of photos we were after and the logistics of covering all of the activities and still having some time to participate.  Head and shoulders shots of smiling people were at the top of the list, of course.  We each got a flash drive to use for transferring our photos each day to Lou whose job it would be to assemble the daily slide show.

Registration opened at 10:00 AM so we took care of that and picked up our 54th Escapade polo shirts we had pre-ordered.  I got a few photos of the Registration area/process, coffee/donut area, and Escapade banners in the WiFi Cafe.  Kelly Hogan, the president of WiFi Ranger, had his magnificent Class D motorhome and matching communications trailer parked just outside the building and we were able to chat with him briefly to thank him personally for figuring out how to get our WFR-MTi working with the Williston Crossings RV Resort WiFi system this past winter.

There were signs of spring at the fairgrounds.

There were signs of spring at the fairgrounds.

Linda headed back to our coach to start working on a project with Butch and Fonda while I stopped at the AG building to take a few photos of the Geeks On Tour in action.  I also stopped by the RVers boot camp for some photos and then climbed the grandstand to take a panorama of the fairgrounds.  Back at our rig I shot another panorama of our row and then settled in to work on Butch and Fonda’s project until we had to meet with Lou again at 3:30 PM.  We found Lou and Val’s rig and then drove over to Sue’s rig in Lou’s golf cart.  While we were there Lou got Wayne to take a picture of the photography team.

We decided to go to dinner with Lou and Val and headed back down US-33 looking for Culver’s.  Linda and I were able to get nice salads there and split some French fries.  Lou started to drive us back to our site but we kept stopping for photo ops.  One of those opportunities was the Vendor pizza party/social.  We got our photos and visited briefly with folks we knew like Chris Guld of Geeks On Tour, Nick/Terry Russell of The Gypsy Journal, and Charles/Chris Yust of C &’C Marketing (our RV insurance agents).  Escapade directors Bob and Molly Pinner were there along with some other vendors that we recognized.  Molly invited us to stay, which we appreciated, but we are not RV vendors and this was their social.

Terry Russell, Chris Guld, and Nick Russell at the vendor/speaker social.

Terry Russell, Chris Guld, and Nick Russell at the vendor/speaker social.

The RV vendors are their own little community (sub-culture) within the larger community/sub-culture of RVing.  Many (most?) of them are full-time RVers who make their living traveling the RV rally and show circuits selling their goods and services.  As such they share experiences and perspectives that are different from those of us who just attend rallies and shows, especially those of us who are retired.  They are often at the same events and, even when they are competitors, frequently become good friends.

Wallce Lewis (Escapade Assistant Director), Dortha Hall (Escapade Coordinator), and Jim Guld (speaker) at the vendor/speaker social.

Wallce Lewis (Escapade Assistant Director), Dortha Hall (Escapade Coordinator), and Jim Guld (speaker) at the vendor/speaker social.

We finally got back to our coach where I downloaded photos from our Sony alpha 100 SLR camera to my laptop computer while Linda downloaded photos from her Samsung Galaxy S III smartphone to her laptop computer and then onto her SKP flash drive.  I used Microsoft Image Composite Editor (ICE) to process the two panoramas I had photographed and then transferred everything to my SKP supplied flash drive.  We walked over to Lou and Val’s 5th wheel and visited for a while as Lou downloaded the photos from the flash drives and took a quick look at them.

We decided to take the long way back to our coach by walking through some of the campground areas we had not yet visited.  Thick clouds had moved in and the skies to the west were getting ominously dark.  Several people stopped us to let us know that possibly severe storms were headed our way portending damaging hail and wind gusts of 70 MPH.  We shortened our walk and headed back to our rig where we found Butch outside talking on his cell phone.  We put up the two awnings we had down for sun shade and stowed our chairs and end table.  High wind and awnings don’t mix well.  Butch and I chatted until the mosquitoes got bad and then retreated to our respective buses for the evening.

Panorama of EC4HFG horse track infield parking area.

Panorama of EC4HFG horse track infield parking area.

It got into the low 80’s today and the humidity was up with the approaching weather, so the coach interior was in the upper 80’s.  We were watching the approaching storms on our weather apps and the weather/radar sub-channel out of Ft. Wayne, Indiana.  It was a fairly aggressive system but showed signs of dividing and going around us to the north and south.  The rain eventually started, forcing us to close our ceiling vents and narrow our window openings.  Serious lightning developed and the rain intensified to the point where we had to close the large entrance door window and reduce the awning window openings to about an inch.  With a forecast of continued rain overnight and a low of only 65 degrees F we knew it would not be the best night for sleeping.  Still, I love storms and enjoyed seeing/hearing nature’s power while I worked on blog posts for yesterday and today.

 

2014/05/10 (S) Goin To Goshen

We were up at 6 AM with our sights set on a 7:30 AM departure.  Most of the supplies that still needed to be loaded onto the bus were staged in the front vestibule, on the dining room table, or the bathroom counter.  It took several trips to get everything on board, including the cats, but it was an easy final loading process.  We are getting better at this with practice but it certainly helped having the bus parked with the front door opposite the front door of the house.

With everything on board we did the final preparations on the car and bus, pulled the shore power cord, and stowed it away.  We finished closing up the house, checked the lights on the coach and car (they were all working), arranged a few things on the interior, and were ready to roll.

The cats had already sought the safety of their travel locations under the front passenger seat even before I sat done in the driver’s seat.  The big Detroit lit right up and as soon as the oil pressure came up I engaged the high idle to make it easier to build the air pressure and switched the suspension to drive mode.  When the air dryer “sneezed” (purge valve opened) I turned off the high idle, pulled up the tag axle (to shorten the turning radius), put it in gear, and pulled out of our driveway.  It was 7:30 AM.  We made our way up to M-59 and headed west.

It was a chilly morning, though not as cold as earlier in the week when I reset the tire pressures and the TPMS sensors.  I quickly discovered that I had cold air coming in by my feet and shortly thereafter realized that I forgot to open the air supply to the louvers for the air-conditioner compressor compartment behind the front bumper.  When the louvers are open that compartment allows outside air to get into the bay under the driver’s seat and from there into the cockpit, especially at highway speeds.  The louvers require air pressure to close and prevent this air intrusion.  Rather than pull into a business or shopping center I decided to continue on to I-96 west and stop at the rest area at mile marker 112 which would allow an easy off/on just before reaching the Lansing area.

As I suspected, the air supply to the louvers was closed.  I usually shut off this circuit when parked to minimize leaks and auxiliary air pressure run time, but this is (obviously) not part of my mental “to do” list yet.  Every trip I say we need to create written checklists, one for departure and one for arrival, but we get busy and never follow through; at least we haven’t yet.

From the rest area we continued on I-96 west along the southern edge of Lansing, picked up I-69 at the southwest corner of town, and headed south towards Indiana.  It was a downhill run from there, or so it seemed, as the pyrometers were often near the bottom of the scale.  We exited onto US-6 and headed west towards Goshen, Indiana.  We picked this route so we could pick up US-33 north and come into the Goshen area from the southeast.  Our initial destination was a Walmart supercenter at the southeast corner of town on the east side of US-33.  Our plan was to meet up with Butch and Fonda who were driving in from Twelve Mile, Indiana.  From there we would have a short, but slow, drive up US-33 into the heart of Goshen and then east on Monroe Street to the Elkhart County 4-H Fairground.  It’s only a few miles but it is slow because of the heavy traffic that always seems to be present on this high density commercial/retail stretch of a two-lane US highway.

The Walmart "stables" on  US-33 southeast of Goshen, IN.

The Walmart “stables” on US-33 southeast of Goshen, IN.

We were in phone contact with Butch and Fonda so we knew their departure was delayed by business and bus issues.  We arrived somewhat ahead of our agreed rendezvous time, and decided to wait for them at the Walmart as long as we could without getting uncomfortable about the possibility of not getting to the fairground before the 2 PM arrival cutoff.   We did some shopping, had a bite of lunch, took some photographs, and played some games on our iPads while we waited.  The Walmart had a “stable” for the Amish buggies and it was full, with additional buggies tied up to the fence line.  You just don’t see that most places, but this is one of the things that is uniquely interesting about north central Indiana.  Butch and Fonda eventually got on the road and were making good progress but we decided around 1:15 PM to go on to the fairgrounds and try to meet up with them there.  That meant they would not have to stop at the Walmart and incur additional time delay.

Like most rallies, the Escapade requires rigs that want to park together to arrive together.  They also want the rigs identified in some way as being together.  For small groups (four or less) they wanted matching ribbons tied to the driver-side mirror.  For larger groups they wanted the arrival planned in advance with a placard in the window of each rig that identified the group and the rig number, 1 of n, 2 n, etc.  Although the Escapade did not provide a rendezvous area the arrival rate had slowed down by the time we pulled in and they allowed us to unhook our car and wait for our friends, who pulled in not more than 10 minutes behind us.

We had a nice chat with the parking crew while we waited and found out that some of them were members of the SKP Chapter 6 – Great Lakes, which covers Michigan.  We joined the Chapter at the 2010 Escapade at this very same fairground but have not yet made any of the rallies.  Chapter 6 is one of the oldest chapters in the Escapees RV a Club and will celebrate its 30th anniversary at a Labor Day rally this year.  The rally will be in Michigan and perhaps we will be able to finally attend.

We were directed to our adjacent parking spots on the east side of the infield of the horse track and got backed in with the assistance of the parking crew.  The fairground was well prepared for RVs on parts of the property that are not set up as permanent RV sites.  Electrical cables emerged from manhole covers and ran to outlet boxes on the ground and temporary water manifolds were placed alongside the power lines.  We only connected the shore power for now, having arrived with a full fresh water tank.  I dialed back the charger section of our Magnum 4024 inverter/charger to an AC input of 25 Amps before connecting the power through to the coach.  This limited the amount of power the charger section would use, ensuring that adequate power would be available for other essential coach functions such as the refrigerator, auxiliary air compressor, lights, coffee maker, and television sets.

We put out our patio awning to shade the passenger side of the coach from the afternoon sun and sat around for a while enjoying a snack of pretzels and almonds along with a tasty adult beverage (us, not them).  Linda and Fonda went for a walk while Butch and I fell asleep.  We woke up hungry and eventually decided to go out to dinner.  We took our car and since I was driving I had to pick the restaurant.  We ended up at a Chinese buffet and all ate too much.  We were surprised to see a lot of Amish buggies tied up outside the restaurant and even more surprised to see so many Amish inside enjoying the buffet.  I thought it was actually pretty cool, just unexpected.  By the time we got back to our buses we were satiated and tired.  We retired to our respective coaches for the evening.

 

2014/05/09 (F) Rally Ready

Today was all about preparing for the Escapees RV Club Escapade.  Large rallies, like the Escapades, are week-long events with non-stop activity from sunrise to well after sunset.  We like to stick to our way of eating, but there isn’t as much time to prepare meals at such events, so Linda spent much of the day preparing and pre-cooking most of our dinner meals for the week. Breakfast and lunch tend to be simpler meals with less cooking involved.  Part of her cooking today, however, was her yummy granola which we will have for breakfast most mornings.

I spent a good part of the day working at my desk on e-mail, website, and blog tasks.  I took occasional breaks to select clothes and stage other items to load on the bus.  On an afternoon break I topped off the coolant in the Aqua-Hot and hooked the car to the motorcoach.

After dinner I wrapped up my desk work, shut down my computers, and staged all of the electronics that still needed to go on the bus.  We relaxed for a while in the evening and by bedtime we were comfortable with our level of preparation and, with only a small number of things left to do, confident of an early departure in the morning.