Bongo Heater, etc

[Derek]

yamaha said:

Derek - never mind sitting watching "Lost" - come down to Somerset for a week and help me fit my new Webasto 24v heater to the Bongo!!

Mike

Hows it going then Mike, do you have the heater working yet?

Derek

[viv]

Even our house feels cold at the moment and the heating is on 24 hours a day.

[yamaha]

Sorry to disappoint you, Derek, but no!! I've got the electronics box sorted - and have sourced both inlet and exhaust silencers, but no metal has yet been cut!!

'Tis too cold outside for a young, sensitive chap like myself to be out scrambling under a Bongo! Poor excuse, I know - but I really am looking forward to getting it done, but it may have to wait till it gets a bit warmer.

Mike

[viv]

Yamaha
Will it ever get warmer, it is really foggy and cold down here. Still I have done all my shopping and now just to collect the turkey tomorrow!
Have a nice warm Christmas in somerset and I am sure the heating will wait for you to fit it later.
Viv

[Derek]

yamaha said:

'Tis too cold outside for a young, sensitive chap like myself to be out scrambling under a Bongo! Poor excuse, I know - but I really am looking forward to getting it done, but it may have to wait till it gets a bit warmer.

Mike

I must confess that the outside jobs are being avoided here, I have plans to put in a 12V socket up in the Hylo luton area for the TV to save running an extension cable each time. I will probably still be using the extension lead next Summer

I am still brooding about putting a heater into the Hylo but we don't want to loose the use of the wet locker. That was why I was looking at the one in the engine compartment but that was about £1500, not really a runner. When you look for spare space in the Romahome it is very hard to find.

Derek

[yamaha]

Hi Derek

Yes, I know what you mean about spare space in the Hylo - when i saw Viv & Terry's very neat installation - in the wet locker, but covered by a plastic shelf - I was most impressed - and it was SO cosy - I think that's what sold me on the idea.

Would there not be any room under the sink cabinet? I seem to remember the bottom of that cupboard wasn't full width - but not sure why. It doesn't really need a lot of space - but you do need to be able to access the underneath for the inlet and exhaust.

The other place that springs to mind - how about under the bonnet, feeding through the bulkhead? Not sure if there's any spare room - and it would probably need doing over a pit for underside access - maybe Ant could come in with a few suggestions on that one.

Just been to a party of our flying club, that's why I'm up late tonight - but must feed the cat now, and turn in.

Mike

[Pauline]

yamaha said:

Just been to a party of our flying club, that's why I'm up late tonight - but must feed the cat now, and turn in.

Mike

Turn in?

Turn into what?

A pumpkin?

[yamaha]

Funny you should say - it WAS a pumpkin - never mind - I'm ARMLESS!! ;D

Mike

[Graham]

yamaha said:

Funny you should say - it WAS a pumpkin - never mind - I'm ARMLESS!! ;D

Boom! Boom! Nice one Mike ;D

[Pauline]

Don't encourage him - he's obviously pulled the Christmas crackers early ;D

[yamaha]

Hi gang

Well, with the weather for the week forecast as dry and mild(ish), I've taken the bull by the horns, and started to fit the heater in the Bongo.

It started off slowly - I was having trouble fitting the mounting bracket I'd made to support the heater in the engine bay - a lack of room to work - but managed to solve that problem.

The next feat of engineering (bodging) entailed drilling a 65mm hole through two bulkheads - with a cheap hole saw! Needless to say, all I managed to do was blunt the hole saw half way through the first hole!! So, off to the local toolshop, and £23 lighter I had a "proper" jobbie that will last a lifetime - it probably will, as I can't envisage needing to drill that size holes in metal very often!!

Revelations - it cut through like a knife through butter - both holes drilled in 5 minutes!! These were for the hot air outlet, which is on the side of the step into the sliding side door, with a swiveling nozzle - the plan is, nozzle upwards, with door closed will heat the van - door open, and the nozzle outwards, it will heat the awning. That's the theory, anyway!!

Tomorrow I am borrowing a 100mm hole saw from my Son - this is to fit the recirculated warm air intake to the front of the engine shroud, in the passenger footwell. All being well, this should be an easier job than the outlet - even though it's a bigger hole!!

After that, later in the week - if the weather holds - the burner air intake and silencer, the burner exhaust and silencer, the fuel pump and supply, the electronic timer panel,................!!

After all that, then I have to rip out my split-charge wiring, and replace it with the magic box of tricks that will supply 24volts from the two batteries for the heater, and 12volts for everything else!!
Luckily, there is a chap on the Bongo Fury site who has already done this job, and has written a great report on how to do it - so I'm really only copying his instructions!!

It would be really nice to have it working ready for our March meeting - depends really on the weather - but at least I've made a start, so that will give me some impetus to crack on with it - I do think that thinking about the job is very often worse than actually getting on with it - especially as one gets older - there is a great temptation to put it off till tomorrow, then it never gets done!!

If this installation proves a success, and I don't blow the Bongo up in the process, the next project will be to fit the Cruise control kit, which has been sitting looking at me since before Christmas!!

I spent much of last week trying to devise a rear wheel cover to keep the draught out of the awning, using the base from a tent, and some fibreglass tent poles. I initially thought it was a success - but one tent pole snapped after I'd finished it - so it went out for the dustman, and we're back to square one with that one!!

Come on, folks - it's gone very quiet lately on here - surely someone has done something interesting lately? Or are you all away camping!!

Mike

[Derek]

yamaha said:

I do think that thinking about the job is very often worse than actually getting on with it - especially as one gets older - there is a great temptation to put it off till tomorrow, then it never gets done!!

Hi Mike

How true, I think of all the probs that may happen and they never do, I was fitting an anchorage for the dog harness which required a hole in the floor. I was concerned about using an electric drill underneath and in the end,decided to use a hand drill, it went through like a knife through butter, very thin tin!

I have been poking around fitting a 12V socket in the luton area, not quite as ambitious as your project.

Sounds like you are getting to the interesting bit, hope it all goes well.

Derek

[Pauline]

yamaha said:

The next feat of engineering (bodging) entailed drilling a 65mm hole through two bulkheads - with a cheap hole saw!

Wow! and to think I get scared sticking a double sided hook to our precious van in case it does damage!

yamaha said:

Come on, folks - it's gone very quiet lately on here - surely someone has done something interesting lately? Or are you all away camping!!

Mike

We are busy working hard to make money to fund this year's camping trips!

Although this morning I sat for 70 minutes in the dentist waiting room, (why do they have appointments?) read three magazines and learned that Arthur Lowe, of Dad's Army fame, was born in Hayfield - is that interesting enough for you?

Oh and the dentist said I had lovely teeth and they are very strong ;D

[yamaha]

Well, today was quite a good day - weather a little cooler, but still condusive to "bodging"!!

I managed eventually drill my 100mm hole - the sharp hole saw didn't materialise, so it was back to the cheap set - eventually this one hole took me about 4 hours - I ended up drilling loadsa holes around the outline, and joining them up with a hammer and chisel (screwdriver, actually!!)

I was then able to mount the warm air intake fitting:-



This is a pic of the two smaller holes I did yesterday:-



I was soon forging ahead - helped no end by copious cuppas from Sue, and soon had the heater in place, and the ducting connected up:-



Strangly enough, I'm really enjoying this project - and it will be a bonus if it actually works at the end of it!!

I did manage to also connect some pipes underneath the heater - air intake, exhaust, and fuel feed. Sorting these will be one of tomorrow's jobs - but I'm a Happy Chappie so far - it's looking good.





Still a lot to do before it's finished - including removing some interior trim panels to fit the timer / thermostat thingy.

After that, it's under the bonnet to rearrange the wiring to the batteries - this is where the whole project COULD go up in smoke if I get it wrong - but I'm feeling quietly confident, and that's half the battle!!

So endeth today's sermon - stay tuned for further thrilling instalments!! ;D

Mike

[moya]

derek said:

I have been poking around fitting a 12V socket in the luton area, not quite as ambitious as your project.

Derek

Have you fitted the socket yet Derek? Roger is still thinking about it. Got the book out and looked at the wiring diagram. He is still thinking.

I cringe at what you are doing Mike. That would really worry me. Maybe putting this socket in is as far as we will go!

[Derek]

moya said:

Have you fitted the socket yet Derek? Roger is still thinking about it. Got the book out and looked at the wiring diagram. He is still thinking.

Hi Moya,
I have moved my reply to the technical section
Here

Derek

[yamaha]

UPDATE - Read all about it !!



This is the hot air outlet on the sidestep

Today was a milestone day - after tidying up around the fuel pump, and priming the fuel lines with diesel, I connected up an old pair of batteries from Sue's wheelchair, said a couple of prayers, and switched it on!

Lots of flashing from the indicator - traced to a bad connection to the fuel pump. This fixed, I said a few more Hail Mary's, and tried again.

SUCCESS - the motor started - the fuel pump started clicking - the spark plug sparked - and afer a minute or so - HOT AIR !! ;D

Wow - it's great!! The swivelling nozzle (pictured above) works well - makes it a dual purpose heater.

So that's the mechanical part almost finished - just have to remove some side panels and fit the thermostat, then it's the wiring to tackle!

So, the job's a goodun - so far. I think it will be great to sit in the awning at Devizes, waiting for you all to bring me back my supper, and a drink, from the Pub.

Mike

[wendy]

We're expecting to party in your awning now that it will be so warm.

[johns1]

Hi yamaha,
I was most impressed with your work on the heater installation and your photographic record of it. I hope that all this activity hasn't interfered too much with your training for the Devizes walking weekend. I hope that you've studied the aerial photograph of the site etc. and seen that the pub should be within your range

[yamaha]

Hi John & Wendy

Thanks for your kind comments - the heater install is in the penultimate stages - it's up and running from a couple of external batteries, and today I started to wire in the magic box of tricks that will give me the 24v to run it.

A slow start today, due to the weather, and having to shop for some heat reflecting material to stick on the inside of the sliding door, which is very near to the heater outlet - don't want to melt the trim!!

Hopefully, if the weather is kind tomorrow, I should have it running from the van batteries, provided everything works as designed!!
Then it's just a case of tidying up the cables, and checking I haven't missed anything.

As for the training - yes, I looked at the map, and it does just about look a reachable distance, provided I don't tire myself too much during the day!

Hope my joke didn't offend anyone - it WAS a bit near the mark - I won't post any more - don't want to get told off by the lady with the perfect teeth!!!


Look forward to seeing everyone, plus some new faces - hope the weather's kind to us

Mike

[Pauline]

yamaha said:

Hopefully, if the weather is kind tomorrow, I should have it running from the van batteries, provided everything works as designed!!
Then it's just a case of tidying up the cables, and checking I haven't missed anything.

Snow forecast for tomorrow, let's hope the heater works so you can use it as you tidy up!

yamaha said:

Hope my joke didn't offend anyone - it WAS a bit near the mark - I won't post any more - don't want to get told off by the lady with the perfect teeth!!!

Yes she's got a nasty bite ;D

At least you gave forewarning so people had the choice to look or not (bet they all did!! )

yamaha said:

Look forward to seeing everyone, plus some new faces - hope the weather's kind to us

Mike

Looking forward to meeting up with you and Sue again Mike - can you add some extra outlets to your heater that we can all hook up to?

[yamaha]

BREAKING NEWS - Read it here first!!

Guess wot - it is all in AND working as designed!! Today was lovely(ish), so managed to start work at the crack of dawn - 9.30am.

Managed to follow my wiring diagram without mishap, and soon there were no more wires to connect! With some trepidation I refitted the fuses - one by one - no nasty flashes or bangs.

With my meter I established that indeed 24 volts was available where it should be, so naturally I HAD to test the heater once more, this time running from the van. Great.

Next was the worrying bit - I had to start the engine, allowing the relay to energize, paralleling the two batteries for split charging.

Couldn't believe my luck - no blown fuses - and both batteries being charged from the alternator.
SUCCESS !! ;D ;D ;D ;D ;D ;D ;D ;D ;D

All that was left to do was empty the van of all the tools, nuts and bolts, and discarded bits of wire.

I still have the Cruise Control kit to fit at some stage - it's sat looking at me as I type - but it can wait !!

Mike

[wendy]

That is really great news. Now to get the party organised in that hot awning................
We've got cruise control and it is great - only downside was that we had to pay someone a lot of money to have it fitted, but well worth it.

[mike and heather]

Excellent news, Mike - we've got our heater ready fitted in the Dimension - it works well! I would hate to have to do what you have achieved. Well done. ;D

What's the weather like in Zummerzet? I suspect it's not snowin' like here in Gloucestershire.

mike

[yamaha]

SNOW ? Wot snow?

Baint got none round these 'ere parts!! Had some heavy rain and winds - but it's sunshine and clear skies here now! Bit chilly, though!

I've really enjoyed the heater project - I 'spose I'm a bit of a perfectionist, and would have hated anyone else to have done the job - I had a Toad alarm fitted in November, and can't help looking around it thinking " I'd have made that bit tidier"!!

Mike

[yamaha]

More Pics - here is the magic box of tricks that powers the heater from the two batteries;





Although I haven't driven it since - everything SEEMS to behaving itself so far - just like the owner !!

Next job on the list is to fit the removable side skirt, which runs in a caravan awning type rail, and will keep the wind and animals out of the awning. Will post the pics when it's completed - rain has stopped play at the moment!!

Mike

[Derek]

yamaha said:

Next job on the list is to fit the removable side skirt, which runs in a caravan awning type rail, and will keep the wind and animals out of the awning. Will post the pics when it's completed - rain has stopped play at the moment!!

Fine weather forecast for tomorrow young Mike, no excuses now ;D

Derek

[yamaha]

I used a 24inch piece of mud walling, 5mtr long, from a Caravan shop, which slides into a piece of caravan awning rail pop rivetted to the sill. A couple of bungees tensions it all.

The bit left over was then attached with string, upside down, to cover the wheel arch. The top is held in place by a couple of round magnets, nicked from one of my old bike magnetic tank bags.

Looking at the pictures, I think it could do with shaping a bit better to follow the curve of the wheel arch - but with the awning in place, and the sliding door open, it won't show - hope it works!!

Mike

[yamaha]

Hi Moya,
I have moved my reply to the technical section
Here

Derek

How did you do that, Derek?
Can't see any controls for moving postings?

Mike

[Derek]

yamaha said:

Hi Moya,
I have moved my reply to the technical section
Here

Derek

How did you do that, Derek?
Can't see any controls for moving postings?

Mike

Open the source up with "modify", blue it up and copy (put it on the clipboard), navigate to the part of the board you want to move to, start a new thread and paste the post in. Then go back to the original and delete things. You can get clever and put a link to the new thread.

I like the awning skirt, should keep the wind out, I had a feeling that magnets would get used somewhere, they don't stick very well on Romahomes I have to use those pesky limpets.

Derek