Inversion Therapy

I figured out what has done-in my inverter.  But I am a little confused as well.  It has to do with last weekend while I was home.  I had the van plugged in and I was running an electric space heater inside.  I had run out of propane and the back doors were all iced up.  So it was the electric heater that was keeping the whole van from freezing up.  When I unplugged from the house, it didn’t occur to me to unplug the heater inside.  My inverter is not an on-demand type, I have it on a control panel switch.

I even thought about it at the time but I knew it would stop running as soon as I pulled the plug.  I just didn't care beyond that point.  Those Monday mornings, leaving bed and the warm beautiful wife it contains, are not my best times.

Fast forward.  The next night I was hungry and turned on the inverter switch.  What I noticed was it dropped my battery voltage more than I expected.  What I didn’t notice was the little electric space heater must have kicked on.  I popped my food in the microwave and started cooking.

The offending heater...

A little side note here.  When you live with the limitations of batteries it changes your life.  Every time you turn something on you check the battery power level.  Every time. You think of what you are consuming.  I know turning on the inverter means when I flip that switch my battery level drops 1%.   I am trading that for something else. Its one of the great things about living this way.

My inverter is a Tripp Lite APS 1250, so 1,250 watts with the ability to supply up to 2500 watts for a short burst.  This was one of my early investments after buying the van.  I read about it on some van life blog and the author sounded so convinced it was perfect.  And who knows, maybe it was for him.  But for me, not so much.

Inverters come in three types.  Their basic function is to turn the 12 volt DC you have coming out of your battery bank into 110 volt AC just like you have coming out of the wall at home.  Here is the thing though, not all electricity is created equal.  We don't need to get into a bunch of complicated electrical theory here…

What comes out of them is what makes them different.  —The type of alternating current, or wave.  First off, the cheapest, is a square wave.   If you are paying less than a hundred dollars you might be thinking you are getting the deal of a lifetime.  You aren’t.  Unless it specifically mentions one of the other two types you are getting a square wave inverter.  It won't work for you.  You will regret it greatly. Appliances can’t consume this type of power without damage.  Electric motors in particular.  So don’t go here, it won’t work for you.

The better inverters have a remote control panel that
will let you turn them on from inside.

Then there is the type of inverter I bought which is called a modified sine wave.  These tend to be in the $300-$500 price range and are certainly much better than the square wave type.  But, they are not perfect either.  I could tell my microwave didn’t like it.  It was very noisy when I was running on inverted power.  Even unhappier was my guitar amp.  The electrical buzz coming out was even louder than the music.  Totally unusable, I ended up buying a small practice amp that would plug into the 12 volts.  That did solve the amplifier problem.  What I couldn’t buy at twelve volts though was a loop pedal.  They all run at nine.  So I wasn’t too happy with my purchase.  Honestly though I don't amplify much anyway.

What I should have bought was a pure sine wave type.  More expensive (naturally) but your appliances and electronics really don’t notice any difference between this and electric company power.  My microwave won’t sound like it is in agony and I will be able to hear every single missed and out of tune note on the guitar.

Yes, it is cold in my water storage area!

Finally, the APS 1250 I bought was really too small.  It can really only run one thing at a time.  Here is what happened this week when I turned on the inverter.  The space heater started running.  That little unit sucks up a lot of juice.  It is 1500 watts.  Already it was overloading my inverter by 250 watts but still within that the 2500 watts peak.  Then I started to heat up my plate of spaghetti.  The microwave add 900 more watts.  Now I am sitting at 2400.  The inverter handled it but maybe 30 seconds in it couldn’t take it any more.  Poof.

Something happened I just don't know what.

The inverter has a couple of pop-out fuses.  One on the input side for the charger (this same unit charges my batteries when I am plugged in)  Then the other fuse that should have popped out because my load was too high.  The thing is, that fuse never popped out.  So what happened?  The inverter seems totally dead.  Pushing on the fuse does nothing.

I did some inverter shopping today and it seems like getting what I want is going to cost me six hundred and change.  Plus I will have to wire in a new control panel which won’t be the most fun job ever.  But it will be the cat's meow system. The control panel will give a lot more information on my batteries and their condition.

I am still holding out thinking maybe there might be some other solution that proves my existing system not dead. That would be the best possible outcome. Van life might be cheap compared to domestic alternatives but it sure isn’t free.

The Other Side of the Coin

Its only been about a week since I wrote that last post.  Buried in the low voltage depression of some dark grey winter days.   It even had The Wife writing to me about sounding down and out. But today it is better.  Today is Fat Tuesday.

Mardi Gras. I don't think that my better mood can be contributed entirety to that amazing margarita I just had. But it does have me thinking about warmer places.  Drinks with umbrellas.  You know, the big decisions in life.  Pink or lavender with this one?

It certainly can't be the weather.  We are back into an arctic freeze up again.  Twelve degrees below zero last night with wind.  The furnace ran a lot.  More by luck than good planning I parked nose into the wind.  I don't know how much difference that makes in heating costs but it is great the house doesn't rock around so much.

Ah, but they do make a
fine margarita.  It is a pity it
is fourteen dollars though.

I got my house batteries warmed and charged up real good over the weekend.  I put an electric heater in the battery space and ran it for 36 hours while charging them up.  They needed it.  They were frosty on the outside and swollen.  Barely holding 50% over the night.  The last couple of days I have been waking up to the batteries still being in the mid 80s.  It has been great not having that worry of wondering if I was damaging my batteries.

Living spaces, no matter if they have basements or wheels, are trouble and expense though.  Last night my inverter made an unhappy electrical noise while I was running the microwave and it stopped working.  No lights on the control panel, no lights on the inverter itself.  I checked the circuit breaker and it wasn't popped out.  I unplugged it and plugged it back in.  It did not recover.   When it is below zero and windy that is as much trouble shooting as I am willing to delve into.  But I am concerned what this means in this day of disposal appliances.  That was an expensive item.  Four hundred fifty dollars on Amazon.  On top of this, it was a bad match for me and I never liked it… Still, I am not looking forward to replacing it.

Looking up into the fender, you can see it
is about a quarter full of ice.  Hitting it with
the car wash pressure washer melted it back.

This past weekend was one of ice.  We got another six or eight inches of snow on Friday night.  Spoiling some plans we had for weeks.  I wasn't going any where in the BV anyway, I was letting it thaw out and re-charge.  I didn't bother to clean the snow off of it at all.  What happened though is the snow melted off the roof and down into the door hinge fender areas and building up and re-freezing.

By Sunday morning  it was totally froze up.  None of the doors would open.  I had to take a heat gun to the passenger side door which would at least unlatch and open not quite an inch.  Blowing hot air into the crack on the hinge side of the door, eventually I melted enough ice in the pocket of the fender so I could open it enough to squeeze inside.  From there I could hit it with more heat.  Once the one door was more or less operational I took it off to the car wash to melt out the remaining doors.  I ended up soaked from rebound water.  Big job at the self serve.  Twenty nine dollars.  The most expensive car wash of my life.

Signs of an ongoing project.  A path down the
middle, from bulkhead door to bed.

The BV is a bit of a boars nest right now too.  I am working on enclosing the fresh water tank.  So I have all the stuff that normally inhabits the area next to the water tank, strewn around the floor.  Or stuffed under the table.  Or piled on the countertop.  All flat surfaces covered. Really quite bad in here.  When I get this done though it will be another milestone.  The ability to keep my fresh water tank un-frozen and working regardless of the outside temperature is going to be great.  Plus the ability to tell how much water I have even though I will no longer be able to see the tank.  Wish I could have gotten this done last fall rather than now when winter is (hopefully) wrapping up.

But I tell you what, and I think is at the root of my happiness.  I woke up before my alarm this morning.  Looking up I noticed…  Light in the skylight for the first time this “spring”.  The days are finally getting longer.  My solar panels can work more and my batteries less.  I will have survived two winters of living in my van.

The ice block at my back door.  Opening
the door further would have broken the
plastic body material going around the corner
from the side of the door to the back.

So here is the deal about van life.  You are going to have some dark days.  There will be challenges.  And unexpected expenses.  But for living the type of half life I am needing to live these days, it has been great.  The nomadic life calls to me.  It always has.  This van life, as crazy as it is and for as many times as you have to put up with hearing the “down by the river“ joke, it is still worth it.  It has allowed me to live out a life dream. The option of having the best of all worlds right outside my door in the morning has been great!

Stuff, stuff everywhere!

Feeling Low (Energy)

There is no two ways around it. Sometimes van life gets me down.  Take tonight for instance.  I am low on power.  It has been cold again and my engine battery seems unable to handle it.  I went to start the van last night so I could move to another part of town. I got one weak roll over.  Not enough to fire, and that was it.

Today over lunch hour I pulled the battery out again and brought it into my cubical to warm up and thaw out.  Always a cold finger freezing job when it is near zero.  Other people have a plant in their cube.  I have a DieHard.

Additionally, my house batteries are really low.  We had a nice clear and sunny Sunday.  But there was a foot of snow on my solar panels.  Not much collection happened that day.   Prior to that, and since, it has been cold and grey.

A thawing DieHard on my office floor.

When batteries get weak they can't handle the cold well.  They freeze and don't hold much power.  That is a bit of the cycle I am in here as well.  Even if I plug in to charge, if the batteries are half frozen they won't charge much.

I spent part of my workday today doing some research on small propane heaters.  It seems like I am going to have to somehow heat the house battery space.  But figuring out a way to do this and not get battery acid fumes inside the living space seems the trick.  But at the same time I have to come up with some solution that doesn't suffocate me by burning up all the oxygen in my small space.  So far I have not found the right answer.

I looked at the Little Buddy by Mr Heater.  The size was bigger than I really wanted but the area it wanted for clearance from flammable materials was the real deal killer for my situation.  I just don't have that much space.  There was another small propane heater that screwed on to the top of a one pound cylinder.  But it was built to point up at a 45 degree angle.  No way to change that and really I need to point down 45 not up.

Here is a way to feel even more crowded.
Stack up a bunch of boxes.

What I have done tonight is pull my slide out drawers and have them stacked by the side door.  I won't be warming the battery space but at least the space next to the batteries.  Hopefully that will be good enough to make some difference.

Right now is the lowest I have ever run down my batteries.  You shouldn't run them down to even 50% and I am sitting at 51%.  Some battery damage is likely to occur.  Tomorrow I have to get some sun or I have to get someplace where I can plug in and charge up.

All of this stuff is the harsh reality of van life.  Particularly cold weather van life that can get a person down.  Sometimes it just plain and simple isn't fun to be living in 63 square feet when it is -11 inches away, outside my steel walls. When a few other things go wrong, it all starts to pile up.

At least there is no shortage of white stuff!

Wait, It Gets Worse

So when I last wrote I was a day past the second coldest day of my lifetime. I was home for the weekend. I had the boiler running.  The house was warming up, the family was happy and everything was looking great. 

I was naive.

On Saturday I did my morning inspection and realized the house temperature wasn't really where I expected it to be.  We keep the kids-side of the house thermostat set to 59 degrees (they will work through our parenting in therapy when they get older) but this morning it was 55.  Sure, even with the really great furnace we have it takes hours to raise the house temperature by a few degrees but once there it does a really great job of holding it.  When I saw it was low I had an ominous feeling.

A radiator with a hairline crack running
almost the full length of one fin.  Research
tells me this can be filled with JB Weld.
It seems like a good summer project.

That feeling intensified when I got to the basement. The boiler panel read PR_0.  I have seen that once before. It means Pressure Zero.  Somewhere in the system there was a leak.  To find it I turned on the fill valve and walked around.  It didn't take long.  In a small room off the basement garage where it is our understanding the driver used to live, back in a time where our house employed servants, there was water gushing from a radiator.  It was a foot long split in the cast iron.

At this same time pressure on me was intensifying to get the water working in the kitchen sink.  This is also the families source of filtered drinking water and talk was happening about maybe the need to buy bottled water.  Something I consider fine out of necessity for an event but six people in a house can go through an environmentally unconscionable amount of bottled water in day to day living.

I had been running an electric heater in the sink basin for a few days, but it had just been so cold it couldn’t seem to un-thaw it.  I began to suspect the freeze-up was not actually in the basin but in the garage below the kitchen.  When I did further inspection I found that not only to be the case, but in a way it was lucky because the pipes, old fashion CPVC plastic had split and broken.  Both the hot and the cold.  If it had thawed out in the basement I would have had a real mess. Now added to my task list was re-plumbing the kitchen.  As much as the family wanted a working sink again, it wasn’t going to be a quick fix and getting the heat back on took precedence.

The Pex tubing where the radiator used to sit.

What I did to get around the radiator problem was to just bypass it.  I installed a 3/4” Pex line from the radiator input to its return.  Tightened the whole thing up and moved on.  The basement room would no longer have heat, which is going to cause us more trouble in the bathroom off our bedroom.  The plumbing there will be even more prone to freezing that it already is.  But at the time I didn’t know any way around it.  Since that time I have done more research and discovered a product called JB Weld.  A two part epoxy putty with enough flexibility to stay water tight through the expansion and contraction of the radiator.  I might write more about it later when I actually apply it.

There were two dead cars in my driveway.  I had to replace one battery and brought the other in to thaw out.  It was a long day but by the end of it I refilled the heating system with water.  Got the pressure back up.  Everything was holding water.  The house was beginning to warm up.  I had one bedroom prone to air bubbles in the system that wasn’t heating yet but I was feeling pretty good.  This whole freeze up was behind me.

I was naive.

The cold water pipe to the kitchen sink.
Lucky for me this pipe was still frozen.

Sunday morning I knew everything was fine.  I lounged.  I drank coffee.  I relaxed.  Basking in my confidence of surmounting every difficulty.  About ten we were planning lunch for the family and I went to the basement to grab something from the deep freeze.  What was that sound?  Gushing water?  Is someone running the wash machine?  I opened the laundry room door and discovered my state had added a new lake over the course of the evening.  Lake Laundry. The boiler was back to showing PR_0 and I had new problems.

When things freeze up, they take a very long time to unthaw.  What I didn’t realize is when the pipes froze they had large plugs of ice inside them.  With the basement just barely above freezing it took a long time for those ice plugs to thaw out.  When they did, the heating water could get to places it hadn’t been able to the day before.  Those places all had pipes that had broken in the freeze.  In my case, the cold water return pipe for the radiator in the garage had three broken spots in it.  In the process of discovering that I found the cold water pipe going to the laundry sink was cracked as well as both traps in the drain.  My wife had been bothering me to replace the sink for years, it looked to me like just as good a time as any.

I love how the Pex tubing can be color coded.

By Monday night with the handy plumbing assistance of my youngest daughter we had everything running again.  We used Pex tubing for all the new plumbing.  I drained out the radiator in the garage and determined it had not frozen.  For now that radiator is bypassed as well.   I will plan to hook it up in the summer as another heating zone.  A new laundry sink has been purchased.  We bought a two sided sink and I have cut out the center divider so we can use it as a dog washing station.  And, we have framed in a stud wall in the laundry room so we can insulate it this summer after I remove the window and replace it with some glass block.

So this freeze up was huge.  Record setting cold temperatures made for a record number of problems.  But I guess we got through it.

I love Pex tubing.  It is super quick to work with.  Really
easy to add things later.  And can handle freezing!

The sink with the center divider cut out.  

Trouble On The Home Front

I make no secret that I live on the frozen tundra of the northland.  The last few days the outside temperatures have been nothing short of brutal.  Meanwhile I’ve been cozy as all get out in my Big Van.  Going through a 20lb propane tank in about three and a half days.

Part of the reason for the rapid use is it has been too cold to even go do anything. Rather than walking downtown to visit a pub or go see a movie, I have just been just walking to the van and determining it is too cold to go back out.  So every night I am just hanging out in the van. Running the furnace and needing to keep it…sitting around playing guitar, doing some writing, or van planning... temperature rather than being able to lower it down to the sleeping under a pile of blankets setting.  So yeah, I am burning more propane.

Minus ten below floor temperature
under a few layers of sweatshirts.

The coldest outside air temperature for two nights was around minus thirty two degrees Fahrenheit.  Fairly calm the second night but the first night was very windy too. The BV was rocking! Like I said, sitting up on my bed I was plenty warm.  The floor though was cold.  Particularly in spots.  By the side doors, which as it turned out, were on the windward side.  Around those doors it was very cold and drafty. I put my big coat on the floor in this area.  That helped a lot.  Under my table, which is at the back of the side doors, I threw down several sweatshirts.  Later in the night I checked the floor temperature back there and it was minus ten under those shirts.   I had no idea sweatshirts were such good insulators. 

I thought this was cold.  ...This
was not cold.  It went down another
five degrees.

By the back doors there always seems to be a gentle breeze on my face when I am sleeping.  These two nights of course this breeze has teeth.  I took to wearing a hooded sweatshirt as part of my night attire.  I woke up at one point and felt my nose trying to determine if it could be getting near frostbite temperature. …I don't think it was but it was cold enough for me to decide to roll over.

All of this must sound really miserable, but it is just my life right now.  I look it all as an adventure, and as Bilbo Baggins would tell you, adventures always have some rough patches.  Nasty uncomfortable things, adventures.

But my van life is only half of the life I live.  At the opposite end of the spectrum from the sixty three square feet I live in five days a week is the sprawling manse I live in the other two.  A big old one hundred and ten year old structure I am sure on my deathbed will be the pinnacle of cool places I have dwelled.

When the salty road ice freezes on your tires.

As I lay sleeping one of those awful cold nights my phone rang at four AM.  When I saw the caller ID I knew this could not be good news.

The Wife said the kids were complaining about being cold in their rooms earlier when they went to bed. But what can you expect?  It was only two degrees shy of the coldest temperatures I had ever lived through.  Given the size of the house, we are cheap how we heat it.  The kitchen and our office/bedroom we keep around seventy.  But the rest of the place, including the kids bedrooms we keep 59.  Add wind and sure they complain some.  She didn't think anything of it.

It was the four AM call to nature when she remembered she had not reopened the dining room doors.  Those doors hide the thermostat and we have discovered in the past will throw off the whole house temperature.  She walked to the other side of the house to open them and discovered the kids were not lying.  The house temperature was 43 and the furnace was not running.

We did some debugging over the phone to no avail.  You know, the normal stuff you try.  We power-cycled it a couple of times.  She got some boots on and went outside to check the air intake and exhaust for obstruction.  No joy.

Low sun cresting just over the fence top
at eleven in the morning.

This didn't seem like a situation that would wait until the weekend so I took a day off.  I have a friend who is a plumbing - heating guy and so I am able to call him up for some advice from time to time.  He suggested the trouble was in my flame sensor and told me how to go about pulling it out and cleaning it.  I had to call him back a few minutes later when I pulled the sensor out and a gush of water came out of the hole.

So here is what happened.  The basement got very cold.  As in very, very cold. The condensation pipe coming out of the bottom of the boiler has a trap in it just like a sink drain.  I suppose that keeps bugs from climbing up inside the burn chamber during the summer.  With the cold basement temperature the trap filled with water froze up.  The condensation could no longer drip out.

I hooked up an electric heater to blow on this area while I was cooking supper and about an hour later it drained.  I still cleaned up the flame sensor before I put it all back together.  But then the boiler lit right up.  It took about five hours to heat this barn back up.  Two rooms aren't getting any heat.  I expect the radiator pipes might frozen.  Now with the heat back on they should thaw out.

What a condensation tube trap looks
like and how it changes your life.

That was one crisis abated.  The kids bathroom was frozen up. That is a common occurrence.  It freezes up if it gets below twenty.  In fact we joke we can tell you the outdoor temperature based on what plumbing is frozen in the house.  Still though, setting new records breaks new records. 

As I sit here tonight four of the five bathrooms are frozen up.  The kitchen sink both hot and cold and the laundry room are all without water… So I will have a busy day of it tomorrow and look forward to warmer days ahead.

The flame detector re-installed in my boiler.

A Brass Monkey Night

Tonight is forecast to be -25F.  My coldest previous van sleeping record was -16 one night last year.  I was actually kind of disappointed because we had a minus twenty-two night but it was over a weekend and I was comfy in my bed at home.  I think I will be OK.  I keep telling myself propane tanks work down to -44 so I should be fine.  I have actually considered running a pipe back to my propane storage area that so I could blow some heat back there if I really had to. But really a better idea would be to just get a hotel room (with a hot tub!) if it actually gets that cold.

This past weekend I spent some time rebuilding my plumbing system.  I have a background of house building and so that previous experience warps me for doing what I am now. When you are building a house you want it to all look pretty.  You hide all the pipes in the walls.   Doing that doesn't translate well to van life at all. The outside walls of the van get pretty cold.

It takes pulling out the sink to service any
of this stuff.  Things to consider in the
next design. (file under mistakes)

I was having trouble with freeze ups.  Every time it would get down to single digits… an event that occurs fairly regularly in this god forsaken frozen wasteland in which I live …my water pipes would freeze.  Over time I discovered if I pull out my bottom pots and pans drawer they would thaw back out in a few hours.  It wasn't a hard freeze.  No damaged pipes.  Just an annoyance.

When you are building, as I have learned, in a van you are heating the center space. The air in the middle. Anything not touching that middle air though gets pretty darned cold.  So my pipes, tucked back behind the water tank, got to be closer to outside wall temperature.  Low double digits.

The fresh water tank in contact with the
very cold floor.  No wonder it freezes.

The fresh water tank I purchased had multiple taps on it. I was just hooked to the back ones. My first step was to unhook the old pipe going from the tank to the pump. Luckily I thought ahead when I originally built this.  The pipe had a coupler about mid way. Removing the pipes was as easy as just undoing that coupler.  To keep my options open I cut the old pipe a bit shorter and capped it.  Then reinstalled it back at the coupler.  If I ever need to hook up to that spot again at least it is there.

The other thing I had thought about as a design change, I wanted to lift my water tank up off the floor.  To have an air gap.  Again, this is just as I mentioned, I am heating the interior air.  If the tank is sitting in contact with the floor, it will become floor temperature.  With an air gap, it will have a buffer against that.  I should even be able to circulate air into that space using a thermostatically controlled fan.  I used two strips of one inch foam insulation, one under each side to make this air gap.

Auto sound proofing.  It is adhesive on one
side, you just have to heat it to pull the
paper off.

The next job was to move my pump upward and out somewhat.  Previous to this rebuild The pump was mounted to a half inch hunk of pine (that warped).  Then the pine was attached to the wall of the floor to ceiling cabinet with a folded cloth napkin that I think I stole from an Indian restaurant in-between. This napkin was meant to reduce vibration noise.  To that end, I think it worked fairly well.  But it was thicker than it needed to be.  Putting the pump very close to the sink and in general just looking sloppy.  I replaced the pine with some 1/2” plywood.  The napkin with some auto sound proofing mat.  This is the stuff the wealthy teeny boppers use to keep all the boom-boom-boom from their over priced sound system in their car.  It worked great for this pump job and it is loads thinner.

Then on to the piping.  The tank has to have each tap drilled out before you can use it.  I drilled a 5/8” hole, trying to be very careful to not get any of the waste plastic bits inside the tank.  Then I ran 1/2 CPVC pipe up over the front of the tank and pointed it toward the new spot where the pump is attached.

The tank up on blocks.  No longer in contact with the floor.

Here is where I tried to do something again where I had failed before.  Back when I first did the build I purchased a water filter.  It isn’t for flavor, it is just a large particle filter.  So if I refill my tank from some camp ground and there is sand in the water, it won’t damage my pump.  Before, when I got the filter I installed it the day before The Wife and I went on a week long camping trip.  Mistake.  Never install something major the day before you go on a trip with your other half.  It won’t go well.  The second day into the trip I was re-plumbing to remove the filter because it didn’t seem to be working right.

You can't see this real well. But I
warmed up the CPVC pipe with a
torch and bent it to create a custom
hunk of pipe.

The same thing happened when I installed it this time.  I think some how, some where, this filter is allowing air to get sucked in.  The pump won’t stay primed and the faucet would sputter and blow air, splashing water all over just like the last time.  I don’t understand it but at least I wasn’t on vacation.  I guess I am going to give up on the filter idea.  Hell, with my record, the van will run out of propane again and the pump will freeze and crack long before it dies of sand poisoning.

My last part of the project was to move the tank vent backward, closer to the pump.  The tank has to be vented.  And I wish I could find some smaller vent filter.  But this works.  Before it was sticking out a bit too far and prevented me from building an attractive cabinet face.  Moved back, as I have it now this won’t be a problem.  One thing I did that was a little bit special for this is I heated the pipe up with a torch and then bent it to create sort of a pair of custom 45s.  This isn't something I could have done if there was water pressure on the pipe.  But for a vent it worked just fine.

Here is everything all put back together.  Next I will be
building the cover to go over all this and makin' it
look all purdy. :-) 

All it all it was a good two day project.  It will work much better than what I had.  Maybe still not good enough to protect me at -25.  But I would think it will get me down to zero with no freeze ups.   Next week I am hoping to build the fan and front enclosure to do the air circulation and protect me further.

Keep warm van lifers!

The Big Short

The shop I work at has been undergoing a huge remodel so I haven’t been there as much as usual lately.  I have been working on some of these non-shop odd jobs like the security upgrade I just finished and a few other things.  But tonight I was sort of in the vicinity so decided to spend the night here for a change.  It is much quieter sleeping in this industrial park area surrounded by residences than it is next to the train tracks or on a busy street in front of one of my usual haunts.

It was funny though.  There were some very smug hipsters working on building out a stealth camper at the shop tonight.  I stopped to observe them for a bit.  They had some big money into their project.  A newish high top, all white and shiny.  I would have loved to have that kind of budget for mine.   With them, however, observe was all I could really do.  They already knew everything so there was little they could gain from me.   I was looking at their sloppy insulation job.  Un-faced ridged foam on the ceiling with large open cell expanding foam between the pink foam and the frame members.  No vapor barrier!  Just 1/4” tongue and groove (of all things) over the top.

What happens when the puck lights get too hot in the
summertime. They melt.

I had hopes maybe they were building it to drive south and stay where it is sunny and seventy all the time.  …Alas, no.   It is staying right here in this cold climate.  Here is the thing, built this way they are going to have huge condensation problems.  Living in a steel box, the enemy is water.  Humans wash with it.  Cook with it.  Eat with it.  …and expel it on their own.  Think about your breath outside on a really cold day.  You think all that water vapor isn’t coming out all the time?  Or the steam coming off a plate of food being heated in the microwave. That water vapor is going to migrate itself right through all those cracks in that tongue and groove, through that open cell insulation and to the cold steel skin of the van itself.  There you will either have a mold problem, a rust problem or both.

What they should have done was put up a layer of plastic film.  I should have done this too even though I used foil lined insulation and metal taped all the seams.  I still get some condensation.  Second, if they wanted to use the tongue and groove beadboard they should have done an underlayment of painted plywood.  A lot of the information online is written by people who are smart enough to not live where I do.  But, that climate difference allows them to do it wrong but get away with it.  Here, when it is bitterly cold, this problem is going to be huge.

The newly built and very heavy duty side door
curtain rod holder. But the screws go into where
many wires live.

A second problem in the Hipster van, their puck lights were placed tight against the pink foam.  No way for them to dissipate heat.  The only good side of this are likely the light will overheat and be ruined fairly quickly.  Or, if it actually progresses to some fire, at least you don’t tend to sleep with your lights on.  They should be alerted to the smell and the smoke as long as they are there.  But these lights need a little bit of air gap.  Again, my foil lined foam helps me here but this is a summer problem.  Imagine how hot it is beating in the sun.  Now imagine you hop out of the van some morning and forget to turn off the lights.  They are gonna get damned hot.

I never claimed to have made no mistakes in my project.  I spent last weekend fiddling with one that will continue to haunt me, but that I got working for now.  How it manifested itself was the main two overhead ceiling lights stopped working.  I noticed this problem as I was getting the van packed up for The Wife and I to head north for our annual parents only camping escape.  First things first, I checked the fuse box and indeed did find a blown fuse so I made to replace it.  When I plugged the new fuse in it blew immediately.  So I had a dead short.

The thick heavy wire that I thought was a good idea.

At that time, I thought I knew exactly what had caused it.  The day before I was in the process of building a new door side curtain rod.  The one I installed the previous year was Walmart crap and I knew it wasn’t going to last.   I was right.  I think it was the fourth day of use we had some visiting Canadians in the van.  On the way out they got a little caught up in the curtain, breaking the thin plastic of it’s attachment point.  Of course no one can be as sorry and deeply apologetic as a Canadian who has damaged one of your belongings.

Since that time the year before I had a plan to build something better but of course time passes.  A year in fact.   It was just days before our departure this year when I got going on the new version.  I purchased a two inch copper coupler from the plumbing department and did an initial job of flattening it in a vice.  Then, flattened it even more with a hammer and anvil.  To this now flat hunk of copper I soldered a 1” copper cap open side out.  I drilled four holes in the corner of the flat part.  Then I affixed this unit to the frame of the van with some self tapping sheet metal screws.

Even pulling the switch out was very difficult due to
how thick and inflexible the wires are.

Those screws went into the frame where I have run a lot of electrical wires.  I didn’t notice at the time but I was sure what had happened was one of those screws tapped it’s way right into the wiring causing the short and now preventing my lights from working.  To me, that was the only logical explanation.  But the trouble with fortune telling, often it is wrong.

I didn’t get my curtain rod built.  Partly due to this new electrical problem and partly due to not having a metal cutting blade for my band saw.  My design idea hinged on cutting half an inch off one side of a 1” copper elbow so it would fit in closer to the van.  I didn’t have a way to do it straightly.  I can tell you for sure it can’t be done with a sawzall.

So then time passed again until this past weekend   From time to time I have prodded around the area of where I attached the rod bracket I had made.  Feeling in the frame holes to see if I could determine what wire was hit.  I was so sure of myself I didn’t really look into other causes.  The trouble was even though I couldn’t actually reach them, I couldn’t feel any wires in the vicinity of where I thought the pointy end of the screws would be.  I was confused.

Wire nuts are great but as I discovered, only when
joining the same types of wire.

Over the weekend I dug in.  I opened up the box where the switch is located next to the side doors.  I figured from this point I could test the wires with an electrical meter and find what wire was grounded.  What I found instead, once I got the box opened up and pulled out was even more confusing.  The wires tested good. I popped in a new fuse.  The lights worked fine!

I had been living without overhead lights for about two months at this point.  Not like a huge, huge inconvenience in such a small space with other lights. …Not to mention the long summer days with light pouring in the ceiling fan dome.  But yeah, I was kind of disgusted with my lazy ass self for not checking into it more earlier.   I turned the lights back off and put the switch box together.  Flipped the switch to turn the lights on.  Poof!   Another blown fuse.   Ahhhh.  I see.  I have learned something.

Here was my mistake.   I did a lot of reading before I did any building.   I read that bigger wire was better for DC current.  You get a lot less voltage drop when you use larger wire for longer runs.  The longest run I had was this one, from the fuse panel to the front of the side door and then to the floor to ceiling shelf and then to the lights.   I just happened to own some heavy gauge wire that I bought two houses ago.  Some #10 three conductor with ground.  House wire, solid core.  I thought this would be perfect.

This wire was not perfect from the very beginning.  Just to give you a bit of background.  Wire comes in two types.  Sold core, which is one strand of copper in the gauge you purchased.  It is heavy and inflexible.  This is the kind of wire you have in your house, running through the walls. The second type is stranded.  Take a whole bunch of little thin copper wires and twist them together to make up the diameter of wire you need.  Stranded wire is very flexible.  At home it is the wire that goes from a light or appliance to the wall plugin.  Its flexibility allows it to handle plenty of bending and abuse.

So there I was, trying to bend this thick heavy wire around corners in my van.  It was hell to get in place.  But now, a year and a half later I am discovering a new problem.  The short, that causing my fuse to blow was because this stiff wire was rubbing against the side of the switch box.  In the course of time, the insulation rubbed off and now I have a bare spot on the wire.

What I did to fix it was cut the wire back and run a short, three inch long bit of stranded wire from the end of the cut to the switch.   It wasn’t an easy job because using a wire nut on two stranded wires, or two solid wires, is easy and works well.  But, with one of each, not so well at all. I don’t know if this is going to cause me more trouble in the future or not.

So no, my build has not been perfect.  I have made mistakes.  I am sure there are mistakes yet to reveal themselves.  There are mistakes yet to be made.  But I do listen.  When I find another van dweller, I am all ears.