New Tires and Shocks

We purchased four new Michelin LTX mud/snow all weather tires (235/75 R15) from tirerack.com that are extra load rated. They replace the original tires on the van, which were in relatively good shape, but did not have quite as much weight capacity. Fully loaded, the van is near 6,000 lbs, with 4,000 of that on the rear axle so having appropriately load rated tires is important.

While getting the tires installed at NTB I had the van aligned, and the mechanic pointed out that one of our front shocks was leaking fluid. After they quoted me $250 to replace them, I purchased two Monroe Reflex shocks from rockauto.com and had them installed by Catherine’s Auto Repair, our normal mechanic. They replaced the factory original (1982) shocks, and the handling on the van is a bit tighter now. [When recovering after a sharp turn, the van only oscillates twice, instead of three times.] The previous owner had already replaced the factory rear shocks with air shocks which impressed the NTB mechanic.

Posted in Mechanical | Tagged , , , | Leave a comment

Converting 12v incadescent lighting to LEDs

Not counting the map lights up front, our campervan has three 12v lights in the cabin that run off the house battery. Each of these lights is an RV Luminaire Model CXL-12 from the Xantech Corporation. These lights have three 1A fuse style bulbs and a three way switch (off, 1 light, or all 3 lights). I especially like the ability to choose low, high, or off on the lights. However, I don’t like the 1A (per bulb) power draw, which is approx 12.5 watts (per bulb, thats 37.5 watts for a fully lit light fixture). True, a 70 Amp/Hour battery can power all 3 lights at full brightness for almost eight hours (if you fully discharged it, which you should never do), but LED lights are a lot more power efficient.

Luminaire CXL-12 (off) Luminaire CXL-12 (one bulb lit) Luminaire CXL-12 (three bulbs lit) Luminaire CXL-12 internals

I thought about using a Luxeon Star I, III, or V Lumiled, but they would require separate driver electronics to be driven at 12V, and at $6 to $26 each they are not cheap. I’d have to wire three to four in series and/or be forced to use a very large resistor to manage the current (or, spend another 15-20$ for a good constant current driver circuit). To get LED lights that were already configured for 12v operation, I bought an auto work-light for $20 at Harbor Freight. It includes 30 5mm white LEDs in series, plus current regulating resistors. The worklight consumes 0.2A (20% of one incandescent bulb) at 12.5v and puts out about as much light as two of the bulbs (visual estimate). For your $20 you also receive some nice extras, like a cigarette adapter with long cord, battery to cigarette lighter adapter (with clamps), and a plastic tube.

Continue reading

Posted in Electronics, Projects | Tagged , , | 1 Comment

Spare Sparkplug

While trying to find the transmission fluid dip-stick, I removed the engine cover (cowling?) that sits between the driver and passenger seat inside the van. I spent a long time looking down at the transmission for a fluid checking or top-up port.

Engine - Long View - from passenger side

After deciding that “no, I’m not missing it”, I looked for anything that came out of the transmission. And then I saw the 6 foot long pipe (visible in the foreground of the above picture – click the picture to enlarge) that came out of the transmission, curved up past the engine, and went right out to the front of the van under the hood (where it hid behind the air intake hose). A nice “Transmission Oil” cap covered the end of the pipe, and was attached to a 6 foot long dipstick. (Apparently this was before engineers decided to call Transmission Oil “Transmission Fluid” to reduce the number of people who put 10W-40 in their Automatic Transmissions.) Sometimes I wish that Val would buy me that Chiltons service manual so I wouldn’t have to search for everything.

While looking for the ATF dip-stick, I ran into something else interesting on the van. You can see it under the ATF dip-stick pipe if you look carefully, or just look at the photo below for a closeup.

Sparkplug hose stopper closeup

Even though our van is a V8, it comes with 9 spark-plugs. The spare spark-plug is currently being used (along with a hoseclamp) to block a mysterious black hose. Again, having a Chiltons manual would help me figure out where the hose used to go. My best bet is that it’s some type of extra hose that goes to or from the radiator. The van runs like it is, so I’m not touching it unless I need to replace one of the spark-plugs while on the road.

Posted in Mechanical | Leave a comment

Making a Campertop Bed

Our camper van has a penthouse top which raises to give a full 7’2″ of standing room. It also leaves a long opening in the roof of the van that has a steel reinforcing ridge. This ridge makes a perfect place to put a bed at night, but first we had to build one. The dimensions of the hole in the van roof are 37.5″ by 9’8″ long. The bed must overlap up to 40″ wide to sit on the ridge. Of course, we don’t want the bed to take up the whole length of the hole or we won’t be able to climb up. 9’8″ is 116″, so a 81″ long bed (6’9″) would leave 35″ (almost a yard) to climb up and down in.

Backing for Bed Cover Stapled to the Plywood Cover on the plywood

After calculating the load bearing capacity and, more importantly, the cost per square inch of Aluminum, Titanium, and Carbon Fiber, we decided to use 3/4 inch plywood covered by a foam upholstery cloth as our load bearing panels. We wrapped the plywood with the foam, stapled it down, and then stapled the other end on top, after folding the edges over. (We also used 3M 77 spray adhesive to prevent it from dropping away from the center of the board.)

Val, Hanging off Bed
Three 40″ by 27″ panels give us an 81″ long bed. The panels stow in the steel ridge below the top when it is lowered (part of the top leaves enough room for two of them to stack). Although they reduce the headroom in the rear of the van by a few inches, we don’t really need it when the top is lowered. When we make camp and raise the top we simply prop the panels upright at the front of the van. When it’s time to go to bed, we lower the panels back down into the steel ridge, cover them with bedding, and climb up into the penthouse.


Posted in Projects | 1 Comment

Transmission Fluid: Also Neccessary!

Van being off-loaded from the tow-truck A few minutes after getting propane, our navigator directed us across the freeway we were supposed to turn onto and into a hilly suburb. Our transmission had been acting a bit squirrelly, but on one of the hills it completely gave out! As we used gravity to back over to the side of the road, we could observe a giant pool of van blood on the road. NOT GOOD!

So after a lot of phone calls to Coach.Net, transmission shops, and tow-truck operators, we finally had the van towed to the only transmission shop that answered their phone on a Saturday and took MARTA home, fearing a $1500 transmission rebuild was in our near future.

Luckily, the problem turned out to only be our 25 year old transmission coolant line which had broken open. As it turns out, transmission fluid is necessary for the proper operation of a not-so-modern drive-train. A new coolant line, a few new seals and gaskets, a filter and new transmission fluid (plus labor, mostly labor) wasn’t cheap, but it was much better than we were expecting!

Posted in Mechanical | Leave a comment

Auxiliary Fuel Pump: Necessary

After getting a propane fill up in preparation for our camping trip, we heard an unfamiliar clicking noise coming from the back under the sink. After we tested the refrigerator fan and house water pump, we decided it was the auxiliary fuel pump. Apparently, it runs whenever the engine is running, but we had never heard it when the engine was turned off. It is controlled by a relay mounted under the hood on the firewall.

I wiggled a few wires and the clicking stopped. Dam I’m good.

Unfortunately, the van wouldn’t start without the clicking noise. Dam I suck.

So I unplugged the wires and plugged them back in, now the fuel pump turns on when the ignition is on, but stays off when the engine is off. Yey!

Posted in Mechanical, Travels | Leave a comment

Propane fill up requires jacking….

We decided to take the van out on a shake-down cruse this weekend (it’s fall break at GaTech, so it was a 4 day weekend) and as the first step we decided to fill the propane tank. The first place we took it to (PECO Camping) had a big fancy propane nozzle, and because our propane fill up port is pointing down towards the ground, they couldn’t get it attached. So, we started the camping trip without a propane fill up, but kept an eye out for other LP tanks. On the way out of Atlanta, we found a U-Haul store with a LP fill up tank out front. They had a shorter nozzle, but it still wouldn’t quite fit. We had to get out the bumper jack and lift the back of the van up just to get the connector attached. So it looks like unless we bring some ramps to our LP fill-ups we are going to have to use the bumper jack just to get propane.

Posted in Mechanical | Leave a comment

Van Utilities

Several of the van’s infrastructure systems are housed under the main bench. Under the Bench

Normally covered by a cardboard box, the water pump is mounted on a bed of foam to reduce vibrations.

Van Water Pump

The “shore power” distribution box is mounted on the side of the bench, with a 20′ extension cord that can be pulled from the outside of the van to external power. (Currently it also has a lamp cord running into the box, but we’ll probably remove that, as we don’t plan on running off shore power too frequently.)

Power Box Shore power cord

Posted in Projects | Leave a comment

New Discoveries!

While cleaning our van, Val made two discoveries. The first was shocking, and the second merely amazing.  Val was looking in a tall cabinet with a clothes hanging rod when I heard her exclaim “Ahh!”, and saw her jump across the van and put her hand over her mouth.  Turns out she had found a mouse. A long dead mouse. A dry and crispy mouse. (As I found out after being elected as chief long-dead-dry-and-crispy-mouse-disposal guy…sometimes being “The Man” sucks.)

After the mouse was thrown out and Val came back to the van, she asked me a question that indicated she had never driven a dodge pickup older than she was. “What’s that thing under the brake petal?” That “thing” was the floor mounted high-lo beam switcher.

Posted in Stowaways | Leave a comment

Titling our Van –or– We have a hobby and antique vehicle

 Hobby and Antique Tag

When we went to transfer the title for our new van, our 1982 original title (filled in by hand with a typewriter) presented the efficient and orderly DMV employees with a challange. First, the lady behind the counter had never seen a title like it before, and at first mistook it for a Tennessee title. (Apparently, Tennessee is behind the times even by Georgian standards.) Continue reading

Posted in Misc. | Leave a comment