1962 Ambassador Restoration – One Bite at a Time

[steinVT]

I am just about to drop a big order for all of my Victron hardware and for my batteries as well and I just got to thinking. If I add a switch and some extra wire, I could use my trailer like a Tesla Power Wall. It also would work as an emergency backup and probably run the water pump, refrigerator and freezer for a couple of days. So would that make it all legitimate for the federal tax credit? If I was adding batteries to my garage, it would.

Here is from Energy Solutions Provider's web site;


What does everyone think? - Mark

[dbj216]

I think it is a good idea. Having a back up is comforting if we lose power for some time. My house is wired for a generator, but I don't have one. Many modern Airstreams are capable of long stays "off grid" with all their solar, inverters, and big battery packs. Gotta keeps the lights on, the fridge running, and the water flowing for our comfort. Being out of town, if we lose power, we lose the well pump, heat and the fridge. Lucky for us our power has been reliable, but I wonder how long that will last.

David

[Tradewind59]

Originally Posted by steinVT

I am just about to drop a big order for all of my Victron hardware and for my batteries as well and I just got to thinking. If I add a switch and some extra wire, I could use my trailer like a Tesla Power Wall. It also would work as an emergency backup and probably run the water pump, refrigerator and freezer for a couple of days. So would that make it all legitimate for the federal tax credit? If I was adding batteries to my garage, it would.



Here is from Energy Solutions Provider's web site;

Attachment 425744



What does everyone think? - Mark

Mark

I think it would be a great idea. We hard wired ourselves for generator In put this year. Feeding in from the trailer...why not?Like David we rely on a well pump here as well. Never hurts to be prepared.

As far as the tax credit I think your covered. Or will be once it's installed along with the bed, kitchen and bathroom. Considered a second dwelling at that point so the credit can be applied there. At least that's how I understand it. Need to research more myself there. Looking forward to hearing about the system Install.

[steinVT]

Well, I finally pulled the trigger. I ordered all of my Victron hardware and my batteries. Buying it on cyber Monday, saved me about $500, but it doesn't come cheap. Looking forward to building up energy system over the winter.

This is the interconnection diagram I will start with. I am sure it will change as I learn more about the units. - Mark

[dbj216]

Maybe consider a couple of outside outlets so other boondockers close by could plug in for a couple of hours to charge their batteries. Charge maybe $10 an hour.

You can be the camping area power plant.

David

[steinVT]

Always fun when the hardware starts to arrive. The batteries and the Victron hardware are in the house.


I also have been spending time retooling the 3D model for the energy storage module. That's what I have been calling the removeable cabinet that will hold the batteries and all the controllers. That should make building the energy system much easier as I can do it on a bench instead of standing on my head. The whole thing will disconnect from the trailer with eight connectors. I will also build a test rig so I can check it out even before it's in the trailer.

Here's a couple of views of the energy module. There are provisions for three batteries, even though I only bought two. If we need it, there will be room. - Mark

[dbj216]

Amazing technology for a 62 Ambassador. The removable energy module is a nifty idea. You probably said already, but I wonder how much it will weigh with the two batteries. And I'm sure you designed it so it will fit through the entry door the way Airstream designs their cabinetry and furnishings.

David

[steinVT]

Batteries are 107# each, the inverter is about 40#. The whole package should be about 400#. In my case with only two batteries, 300#. It definitely is a factor for left/right balance, but is somewhat mitigated by the refrigerator and contents on the opposite side. Overall left/right balance is about 120# to the road side, so not too bad.

The module is less than 21" wide so will easily go through a 26" door with some ramps and a dolly. - Mark

[dbj216]

I figured you had all this figured out in the design phase. David

[steinVT]

Making progress on the energy module. The structure is complete. Now comes the fun part, wiring it all together.

Instead of using buss bars, all batteries will connect to a single positive and negative post with the cables they came with.


This is the side that will face out from under the kitchen counter, probably behind a plexiglass panel. One switch is for battery power and the second is to power the inverter. The inverter pre-charge button is also on that panel. I may attach the Carbo GX display here as well.


Here you can see the inverter, the lynx buss bar and shunt and the solar controllers. The 3 kW inverter is big and heavy.


The final picture is how it is connected to the trailer. There are two 120v 20 amp connectors for the water heater and the mini split. A 120v 30a shore power input and a 120v 30a output to the 120v panel. Four ET90E connectors are not yet installed. They will be for the solar in and the 12v and 24v out.


I need to do more research, however I think the module should be valid for the energy storage federal rebate. I don't think it was in the past but should be with the "Inflation Reduction Act".

This is from the Energy Sage Website:

Energy storage
Currently, for storage (aka battery) systems to qualify for the ITC, they need to be paired with solar and have to be powered by solar at least 75 percent of the time for five years. However, starting in 2023, all residential storage systems (regardless of whether they’re paired with solar) will be eligible for the full 30 percent tax credit as long as they’re over 3 kWh in size.

My system will be connected to my house unless I am camping and is 10.2 kWh, so it should qualify. Kind of like a Tesla Power Wall that just happens to be installed in a trailer. - Mark

[steinVT]

Wow, I can't believe my last post was January. Time flies when you are having fun. Still not yet retired, figure I'll wait until work isn't fun anymore.

Progress has been made on the Ambassador, although not as much as I had hoped. The "energy module" is built and initial testing done. I must say I enjoyed building it on a bench instead of standing on my head under a cabinet.

The idea is this module will be installed on drawer rails such that I can unlock it and slide it out of the cabinet for service. It's AC connections to the trailer will be with three 120v cables; The first will power in from shore power. Second power out to the main AC panel for distribution and finally power out to the hot water heater. The hot water heater will only be in play when hooked up to shore power or when the batteries are fully charged and there is excess solar available.

Here is the connection panel:


Everything being compact has its good and bad. Cable lengths are minimal, good for resistance and cost, bad for getting the covers on and off. This side contains the Orion 24v to 12v converter, the battery protect, the Carbo GX communications hub and the USB computer interface.


I am happy that I went all Victron, it just works together so well. I still am playing with the setup, but its all there. There are at least three communication methods used for all of the components to talk, but I didn't have to develop any of them. They just work. Here is the front panel that will be available behind a clear panel on the cabinet where it will be installed.

This is a screen shot of my phone showing what is going on in the module. Kind of cool, but not sure the real value.


This is the other side of the module containing the solar controllers and the Multi-plus. Everything is tied together with the Lynx buss bar system which also includes the main shunt.


Here are the batteries. A total of 10.44 kw-hr's should keep us going for a while. The batteries are connected in parallel with equal length cables to a post that also carries the main fuse.


Testing so far has been limited to charging from shore power and driving a 120v load. I will have to wait to get it into the trailer to connect it to the solar panels. I am anxious to see how much the 1.2kw solar panels can generate.

After reading a marketing email from Bolus RV, I decided to deduct the cost of this module from my taxes. It is similar to installing a Tesla Powerwall in a second home. We'll see. - Mark

[dbj216]

And welcome back! You're one of the best vintage Airstream builders on these Forums. And what a power plant you have built. Your recommendation of Victron systems will mean a lot to others that want their Airstreams to be strictly sun powered. I wonder what system Airstream uses in their solar option from the factory.

Maybe you need to make a 30 amp 120v connection from your trailer so you can sell your power to other boondockers who have depleted their power supply. "I can charge your batteries in one hour for $100." Make your Ambassador a revenue generator as well as a power plant.

David

[steinVT]

I was messaged by Short563 who is building a new frame for his '60 Ambassador, wondering if I had detailed plans for the axle plates I fabricated for this build. I don't, but managed to find the original plates. I took some measurements and thought it might be worthwhile to display them here just in case they might be useful to someone in the future. So here you go and good luck Short563 - Mark

[steinVT]

Back to our regularly scheduled program, progress has been made on the Ambassador. Last weekend, I managed to completely mask and spray both the epoxy primer as well as the Zolatone. Then on Monday, I went to work so I could get some rest.

This is the automotive Zolatone and it is hard to find. If you need some, don't just blindly order from a vendor on the internet. They look like they have it in stock, but you may actually be backordered for weeks. I finally found a couple of gallons of Apollo Grey so bought it immediately.

Anyway here is a couple of pictures of the setup I used. Make sure you have a good respirator. I actually use a separate compressor (made especially for that purpose, don't use a cheap HF compressor) that was setup outside to supply fresh air to a mask. The automotive Zolatone has very strong odor which in no way could good for you. In addition I had an evacuation fan and input filters that kept the air fairly clear.

Here is the intake.


The exhaust


As part of the prep, I filled in all of the rivet heads with auto glazing putty. That is the little red areas along the seams. Don't think I would do that again. The Zolatone fills so many by itself. On the Safari, I only had to touch up maybe a dozen heads with Zolatone and a paintbrush. Between applying the putty and sanding an excess off, it was a lot of PIA work.


Here is a picture as the epoxy primer is being sprayed. This trailer was heated for years using an kerosene heater and hence had some nasty deposits. I can only image what the lungs of the guy that lived in it full time looked like. This nastiness is after scrubbing with TCP cleaner and sanding with a 220 with a DA sander. That is one of the reasons I went with the Epoxy primer.


And finally the look that makes it worth all the trouble.


Next the marmoleum. - Mark

[Bubba L]

The Zolatone looks great and period correct. It’s hard to get the pressure just right to burst the different colored paint balls. I can’t do it. After we painted our 55, I had a small container of a flat latex mixed to match the primary color of the Zolatone. It comes in handy when you get a scratch or popped rivet later. Marmoleum is good stuff. Keep us posted.

[57Vintage]

Nice job Mark, I don't think I could have dealt with spraying zolatone after spending so many hours getting rid of the original coats of it. The epoxy color and clear was bad enough.

Glad you did all the right things to protect your health. Spent several years of my youth working in body shops and know how nasty it gets.

Harold

[steinVT]

I need to do some documentation catch up on a couple of Ambassador projects and I really didn't like the sound of what I wrote. So I decided to see if Artificial Intelligence could help out. I entered my initial paragraphs into ChatGPT and asked it to improve readability.

This is AI's Response (I added the pictures):

"Let's break down the process for installing Marmoleum:

Preparation:
To begin, I filled all the joints and elevator bolt counter sinks with Pro Fine Patch, as recommended by the flooring supplier. This ensures a smooth surface.

Sanding:
After the patching, I used a belt sander to go over the entire floor. This step really highlighted the vastness of the 28-foot area.


Creating a Pattern:
I crafted a full-size pattern using brown paper floor covering. Thankfully, my supplier allowed me to use their warehouse for this step. I unrolled the Marmoleum, traced the pattern, and carefully cut it out.


Transport and Installation:
Once the cutting was complete, I rolled up the Marmoleum, transported it home, and carefully unrolled it again. After a test fit, I folded it in half, applied adhesive, and then laid it out flat. To ensure a secure bond, I used a 100-pound roller from Home Depot. One important tip: if you're using Advantec for your floor, be sure to get twice the amount of adhesive you'd think you need. In my case, it took two gallons. I noticed that Advantec isn't as smooth as plywood, so it tends to absorb more adhesive.


Handling Joints:
The sheet width was about 8 inches too narrow in some places, so I had to create joints. Fortunately, most of them ended up being hidden under cabinets. There are various methods to create joints, but some require expensive tools. In my case, I simply aligned two factory edges and rolled them flat. This technique made the joint nearly imperceptible.

By following these steps, I was able to successfully install the Marmoleum flooring."


Not bad, then I asked ChatGPT to add some humor.

Here is what it came back with:

"Time to embark on the great Marmoleum adventure! Picture me, armed with Pro Fine Patch and a trusty belt sander, ready to take on a floor that seemed to stretch for miles—28 feet to be exact. It was like a workout for both my DIY skills and my biceps!

Next, I became a floor-fashion designer, crafting a full-size pattern out of brown paper. Thankfully, my supplier generously loaned me their warehouse for a bit of Marmoleum couture. Cutting into that pricey plastic felt like a high-stakes fashion show—it was all about precision!

After a grand unveiling back at home, it was time for the grand adhesive tango. Tip of the day: if your floor is Advantec, it's got an appetite for adhesive that even a marathon runner would envy. Double up on what you think you'll need, trust me.

Now, the sheet was just a tad too shy in width, so I introduced it to its new BFF—joints. But don't worry, most of them ended up in the VIP section under the cabinets. As for creating these joints, some methods sounded like they required a PhD in carpentry and a small fortune in tools. Not me. I went for the "factory-edge-fusion" technique, and voilà, joint? What joint?

And there you have it, folks. Marmoleum: 0, DIY champ: 1. Let's just say, if Marmoleum floors could give standing ovations, mine would be clapping right now!"

It's a new world. Sometimes a little scary. - Mark

[Hittenstiehl]

Very nice write up on your floor install. Good tips for smoother install. Your final install picture looks good. Looks like you went with a gray tone for color.

In a couple of weeks we are headed to LA to look at some in stock Forbo Marmoleum to see if we like it in person. Forbo sent us two samples pieces.

[57Vintage]

Looks great Mark. I chickened out and went with Marmoleum click tiles. The process is easy and they have a couple sizes so the boss decided a pattern was needed.



I did the whole floor and set the cabs and appliances on top. It's been 5 years no issues with buckling or gaps. Great product.

[coloradoup]

Floors look great! Both of yours.