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Lotus54 · 09-04-2023, 08:50 AM

Printed spacers.

Lotus54 · 09-04-2023, 10:03 AM

I took this before cleaning roof with acetone.
I then applied plenty of sealant and screwed down the new flange. It is setting up now. Inside looked good, but I will see about a bit more when I get ready to install fan top.
I will also inspect after a bit, perhaps a good layer of butyl tape/putty will assit, just to make sure.

The spacers worked just right. The two straight ones I did not print holes, but just drilled through. Better to print them, but since it pulls straight down it does not really matter.

Yeah, my roof needs cleaning and some new paint.

Lotus54 · 09-10-2023, 08:06 AM

The new roof vent is working great. I did get some rubber butyl strips to go over the sealant- just to make sure and perhaps give more UV protection.
I tested out the ‘auto’ position yesterday when up working on clearing some trials sections. It came on and kept the interior of the van much cooler. I can see where that will be nice on sunny days when temperatures are higher. It is getting cooler here now and not really needed- but good to know it works well. Fan speed was not full, so current draw was lower and single solar panel easily kept ahead of it.

Next I will fit a second solar panel, it will go over the fan, giving it more protection as a bonus. If I measured correctly, there is adequate clearance.

Lotus54 · 09-12-2023, 08:34 AM

I am planning on mounting a second solar panel on roof ‘rack’ the 2006 AI came with. I bought two panels when I originally got them, since they were discontinued and the right size, so I would have a spare. So I am all set.

Here are the mounts that fit right on the factory ‘rack’. I am not sure what purpose those rails are for originally, except maybe looks. They are adequate for mounting panels and keep them quite secure and relatively low. Only a centimeter or two above the AC unit.

Make sure to get the 2” ones. Do not accidentally order the smaller ones (not that I ever would make a mistake like that…)

https://www.amazon.com/gp/product/B0...0?ie=UTF8&th=1

This is the 80/20 I am using. I do have to drill through for bolts to atttach to mounts, but I wanted as low as possible so did not use the 80/20 with t-slots on both sides.
https://www.amazon.com/dp/B001F0F14O...roduct_details

Lotus54 · 10-22-2023, 02:15 PM

The AGM 100 Ah I’ve had for a number of years is starting to get weak. I got a pretty good deal on this 200Ah Li, the test fit shows snuggles right in behind drivers seat.

I am adding 2nd solar, so this should extend times with my new electric fridge.

Lotus54 · 11-04-2023, 06:36 PM

I designed and 3D printed a ‘3-1’ part for the new battery conversion.
Endplate for battery
Mount for battery main switch
Mount for starting battery Battery Tender.

I came out quite well, I heat-sunk some thread-nuts four the mounting of parts.
I would post up short video of the printing, but I don’t think I can do video.

Once I get it all done I will put up some pictures.

Lotus54 · 11-08-2023, 07:41 AM

All in, just have to install the proper allen head screws to hold shut-off. (Nobody had them locally) and trim the pad in the middle I put in.

It came out great, I also cleaned up wiring, added a fusebox for accessories rather than individual fuses. That is mounted on door side of passenger seat pedastal. The white piece I 3D printed

DaveG · 11-09-2023, 05:56 PM

Quote:

Originally Posted by mrcolin2u

We liked it up there so much we're moving up there next year 👍

Lotus, Congratulations on the new rig! We were just near PA. PNW is great and the Olympic Peninsula is amazing.
+
mrcolin2u - Welcome to WA! We drove over the Deception Pass Bridge Tuesday on our way to Anacortes. Beautiful area!

DaveG · 11-09-2023, 06:03 PM

The link to this thread was in my email - didn't notice it took me to the beginning, or notice the date either

Gotta pay more attention

Lotus54 · 11-09-2023, 06:24 PM

Quote:

Originally Posted by DaveG

Lotus, Congratulations on the new rig! We were just near PA. PNW is great and the Olympic Peninsula is amazing.
+
mrcolin2u - Welcome to WA! We drove over the Deception Pass Bridge Tuesday on our way to Anacortes. Beautiful area!

Yes, a wonderful place to live.
As you noticed, I’ve had it a few years now and just doing things now and then to make it work better for our use.

A second solar panel is next (I have everything, just need a nice day when I have time and not doing other stuff).

For those interested in such silly things, I just picked up Lotus #9.
67 Elan -

Lotus54 · 11-21-2023, 08:34 AM

For any interested, this is the LifeBlue app. I can connect from inside the house, which is handy to monitor temperature, charge state and if charging etc.

Lotus54 · 03-16-2024, 08:18 AM

I finally took the time to mount my second 100 Watt solar panel. I moved the original back as far as I could, removed the ‘Max Air’ fan cover and changed to a new style fan (described previously) so just enough room.
Install went quite well, I learned a few things last time, so pretty easy. Since I wanted panels to sit as low as I could, I used 80/20 with just one ‘T’ slot. So I drilled a hole through the flat side to pass a bolt though to insert in slot. This worked out great, pretty easy to mark the hole and easier than I remembered to slide the ‘nut’ in and get the bolt started (with loctite).

I picked up some ‘Y’ cabling, so wiring was a snap. Just unplugged original, plugged Y into each panel and into main loom going down into van. All are oversized, so no problems there. Even this far north and very late afternoon it was getting a decent current into new battery- with fridge running also.
I expect this will really help with keeping everything charged up and fridge going during times when not moving (engine charging) or plugged into shore power. I do not usually stay parked for more than two days, but for those times (or short drives) this should be great.

No pictures yet darn it.
(Lotus is coming along very well, for those interested in such things).

Lotus54 · 03-21-2024, 07:56 AM

Here are both panels (100 watt each, Grape Solar) mounted.

Lotus54 · 03-26-2024, 12:38 PM

I did not use the AI much at all over the winter- which is unusual. Normally I used it at least every other week.
So when I went to use it yesterday, I found the heater blower would only work on speed 3 and 4. I know that if just 4 (full) works, it is the fan resistor pack. I have had those fail before and had a spare. I thought perhaps two of the three may have failed, plus that is by far the easiest thing to try.
New pack and exactly the same. Next most likely is the switch in the dash. So I pulled it out (not too bad), did a bit of looking and figured how to snap out the switch itself (four clips hold it in, it comes out the front). I had removed it and had on the bench, figuring I could lube the cables and clean connectors.
After some testing I could see that indeed speed 1 and 2 little points were not working. I couldn’t get in there with my point file, so I sprayed some trusty ACF-50. Worked great!
Put all back together and all works well.

I considered just replacing the control board- but it is almost $700!!!

Lotus54 · 04-07-2024, 02:03 PM

Well…the fan control failed again-while on a trip.
I didn’t want to deal with that again, so I blew the cash on a new controller module. Yes- WAY too much, but that stuff needs to work.

Popped it in this morning, all works great.

Lotus54 · 04-07-2024, 02:22 PM

At Steptoe Butte. (Not far from Steptoe, WA) Man, I need to clean the roof! Plan on removing TV antenna, since I never use it.
Steep climb, but no problem. I did not go to the very top, since I did not know a great parking area up there- but just a very, very short walk up.