Think I found my leak. The saga continues
Coolant leak next to bottom froze cracked pipe also. Was having to add several gallons in the last miles of the last trip
Scott
Rebuilding Aqua Hot (https://www.foreforums.com/index.php?topic=39054.0)
YIKES! That's a shame that happened. Other people here have rebuilt their AH systems, so you will have lots of help if you choose to do it yourself.
Ka Ching!!!
dsd, sent you a pm
Original topic here Aqua hot water leak (https://www.foreforums.com/index.php?topic=40399.0)
Yes definitely rebuilding myself. Good fun. I knew it was probably bad before we went and picked up coach. Budgeted 10 K and I'm planning on spending $500 or so
Just part of the list.
Scott
Another really good writeup on DIY from Rob and Matthew a few years back (note there is some discussion/debate on which is the best ID/OD copper tubing to use....)
Aqua hot Rebuild (https://www.foreforums.com/index.php?topic=28387.0)
Yes they talk about 1/4 inch tubing. Mine does not have that. It does have 1/2 OD tubing which I have never seen. Possibly metric, but at this time I do not know. Called my HVAC buddy to check on tubing. I understand they come in three thicknesses. Red thin, blue heavy and some other color that is military grade Thick? I'll order the heaviest I can and hopefully a single length. Spoke with Rudy and am looking forward to the whole project. He has really good proven knowledge. So much easier to learn from others. Good group support sure makes taking on new problems without having to loose sleep easier. Thanks
Scott
I can't imagine getting enough flow through 1/4" tubing for the shower. When Rob and Matthew posted a picture of their tubing it looked like 1/2" to me. I called Aqua Hot and they told me it was 141' of 1/2" of double walled tubing.
Curious what double wall tubing is? It's difficult to measure accurately but is between .025-.032 thick . Describing as double wall seems it would be thicker? Not my field but I'll find out in the coming week. Dean Richner owner of Richner Air in Boulder City is my go to guy for such items. He is looking into it.
Scott
Might be double wall in a different context, but based on this article, it is essentially a tube within a tube used to ensure separation and leak detection between potable water and the heat transfer fluid.
Safety Tubes (https://www.wieland-thermalsolutions.com/en/products/finned-tubes/safety-tubes)
Last one I fixed we used standard 1/2" Copper Refrigeration Tubing from our local Barsco HVAC supply company.
Mike
Not on mine. Single wall .025-.032 thick wall. Mike has the correct tube I think. This is why I am sourcing threw a HVAC source.
Scott
I have removed and can start getting parts and supplies
Scott
Keep the pictures coming Scott. You are getting right along on your list.
Coils removed. Heat compound hammered off with needle scaler. Ready to sand blast
Scott
Sandblasted and ready for primer
Catalyzed epoxy primer two component. Just what I had available on hand
Sort of airplane green
Looks like zinc chromate.
Yes was originally aerospace timed out primer, once it's shelve life is over it's scraped. I'm disposing hazardous waste for them for free by using. Chromate have almost been banned everywhere. Bad stuff. Good primer
Scott
Ordered 150 foot continuous 1/2 OD heavy copper tubing $200
And McMaster-Carr sells mastic. $40 gallon and $14 shipping next day delivery
I figured it would take ten days to get both to get started assembly but hopefully will be able to on Wednesday. Would of lost that bet for sure. Probably will get lost in shipping now I mentioned it.
Scott
Made adapter plate to mount tank to rotary table. Will operate it with electric drill and Variable transformer to control speed. Kinda cheesy but I'm only building one. Will mount this to my welding table. 1000lbs
Scott
AMERICAN INGENUITY AT IT'S BEST
Chris
Very Nice.
Way too good. Fantastic
Just found this thread. It looks great what your doing. finding continuous tubing will bring great peace of mind. It looks like it will be a first class job. Keep the pics coming. Someone down the line will be sure to appreciate any and all documentation. When it is all done, your knowledge for the AH and sense of accomplishment will go a long way.
Larry
Made possible by People like you Larry and everyone else. That has blazed this path before. All the tricks and insight worked out prior genuinely helps.
Scott
Thanks, but I too learned from those who blazed the trail before me and left the info on this great forum.
Larry
Just checked my set up getting ready to wind tomorrow. Rotational speed down to one revolution per 3 1/2 minutes can easily speed up if wanted
Scott
Wow... That's a nice set-up. Could be a possible side business as well. You got extra zinc chromate? LOL.
If I want a side hustle, I'd go back to work. Pays way better
Scott
The coolant leak I was also having at the aqua hot was at one of the solder joints. Who ever messed with this only had a 1/8 inch of insertion into the 90 deg elbow and poorly soldered. Short and cold. Glad it didn't pop apart on the last trip when it started leakin. Very preventable.
Scott
How preaty
We are going to need some video of your turn table at work! 8)
8) Scott, I wanna hang out with you post-apocalypse!!! :))
Scott I'm sure that much copper was next to nothing!!!
Chris
Cheap $200
Where from?
i have sae problem i start mine soon
Is that 1/2 inch tubing as to me it looks like 3/8 tubing. It just may be the picture.
So it's 1/2 OD tubing. Used in the HVAC field. I had never seen before but it exists. Water plumbing that I'm used to is 1/2 ID. I sourced thru a HVAC Friend of mine Dean Richner and he purchased thru one of his suppliers that sends out the exact length to there service people. They cut to length off a (guessing) 1000 foot roll. He was able to get in 24 hours to me. It was rolled about four feet across. I haven't measured thickness but this was my only choice Dean said it was thicker than my .030 I removed. I'm sure you have a similar source near you that can also cut to length.
Scott
I've used lots of half inch tubing before, looking at a picture is hard to get dimensions. Keep your comments and pictures coming
and good luck with the job.
I tried loading video yesterday but said it was not a acceptable format. I'm not tech savvy. iPhone/iPad
Scott
Replaced tempering valve. PO had marked current setting and I duplicated and marked mine in blue. Makes for a nice starting point possibly
Scott
Delayed but getting closer. DW has become #1 project saboteur with her projects. Will have real help tomorrow.
Scott
Needs to be uploaded to a site like YouTube, then post the link to the video in your post. The forum software will let folks click and view.
Scott, can you provide some details on the "turn-table" you are using? I am not familiar with that device. Do not imagine I would ever need one, but curious.
VERTEX 3900-2332 Horizontal/Vertical Rotary Table, 12": Amazon.com: Industria... (https://www.amazon.com/VERTEX-3900-2332-Horizontal-Vertical-Rotary/dp/B00V2YTKKO/ref=sr_1_5?dchild=1&keywords=rotary+mill+table+12%E2%80%9D&qid=1604281411&sr=8-5)
Amazon.com: Electric Drill, 3/4 In, 350 rpm, 10.0A: Home Improvement (https://www.amazon.com/Milwaukee-1854-1-4-Inch-Drill-Jacobs/dp/B00004T16N/ref=sr_1_1?crid=2NQDWYQ52W4XP&dchild=1&keywords=milwaukee+3%2F4+drill&qid=1604281558&sprefix=Millwaukee+3%2F4+drill%2Caps%2C234&sr=8-1)
Scott
Scott,
Very nice work you're doing, there, on your AH rebuild. I like your "powered" rotary table. ^.^d I always enjoy seeing others save time/effort/money using crafty improvisation.
Greg
for those that don't know, Scott is using tools found in a machine shop setting. Shop vernacular is making chips-- I started doing it about 30 years ago and I know others on the forum that have been or still are involved in the trade.
Chris
Hopefully won't have a problem with copper feeding off roll. Currently my only worry. I put in a ball bearing axle in the spool but it's a lot smaller radius than I would like. Will have a body watching it roll out or helping to feed it to prevent a kink in it. The nylon tensioning black plate has about ten pounds of tension. There is a variable transformer on the drill and it will start slowly from being fully stalled. Mastic is going in a grout bag and will figure out what works good after we start. May end up with hand applied to drum and turn onto the layer of it. I'll reach out do DavidS and ask him what worked good for him. If anyone has mastic imput it will be helpful, or for that matter any insight.
Scott
Had to Google it, I'm even more confused
Vernacular
Vernacular is a women's clothing store with a curated mix of Apparel, Accessories, Jewelry and Gifts. Locations in Columbus, Ohio, Cleveland, Ohio, Atlanta, Georgia and Dallas, Texas.
Am I missing something?
Pretty sure mine is wrapped with a ceramic blanket for heat and insulation. Bought a 2" thick blanket and wrapped everything with it.. it works wonderful. No mastic at all.
Or are the proud daughters of a tool maker.....
Okay. I purchased two gallons of the heat transfer mastic to put between tank and copper. That was that cement/mortar like stuff I needle scaler removed.
McMaster-Carr (https://www.mcmaster.com/3568K1/)
Will put thermal blanket outside of copper to hold in heat from boiler.
Scott
Yeah, the mass of all that copper going over the small spool could cause problems, but a competent baby sitter should eliminate that. Would it be practical for you to devise a free rotating, vertical axis, table for the copper to unwind from? This would reduce the chance of kinking. Also, I'm wondering if winding at a 90 Deg. angle to the unwinding coil will put a twist on the coil as it's wound on the tank. Something to consider if the copper doesn't behave well during the winding process.
Greg
I was originally thinking the new roll would be smaller that 4-5 feet across. I do have a horizontal rotating table for 1-2 feet. If it runs into a issue I'll unwind down my driveway. Will scratch it up dragging it back thou. I believe that with a constant tension it should behave till it's rolled up on burner. Kinda time limited once you start also. Starts setting up in a hour. Copper is in pure annealed state.
Scott
Not sure if I can write this coherently but I was thinking if you could lay the copper over the tank then as you spin the tank it unrolls the copper in the same direction as the coils. IOW as the tank spins it rolls the copper in the same direction so that it rolls tighter onto the tank? By doing it this way you wouldn't be unwinding or uncoiling the roll but tightening the coils as it winds onto the tank.
About clear as mud and not sure it would work better.
OK Scott your google must be west coast this is my meaning LOL
Vernacular
noun
noun: vernacular; noun: the vernacular
1.
the language or dialect spoken by the ordinary people in a particular country or region.
"he wrote in the vernacular to reach a larger audience"
Chris
That's what I googled. That's what it bought up. Sorry, hope your not mad at me. Just something I had never heard. Still confused.
Scott
Makes sense to me except no way to tension mechanically
Scott
Ratchet strap with a little tension on it attached to something with a solid mount.. almost like those exercise bikes with the belt and the wheel can be tensioned from a little to a lot.. depending on what's needed for resistance ..
Finished earlier. All went well. Zero twist issues. Didn't end up using tensioner, Did by hand while guiding on. Used exactly 1 gallon of mastic with enough left over to cover the top section where the copper tubing had been Annealed before by aqua hot use Real happy it's almost behind me.
Scott
Scott, all you like is "finishing up"
Chris
Ps. and no I'm not mad at you, I got a good chuckle out of it
The long list got a big chunk knocked off it today. Still lots left. Will be nice to get this part behind me. The mastic was quite heavy/thick, had to mix in a pint of water to thin out enough to use in grout bag. Ended up with a extra gallon of mastic for some other project. It's already in the paint fridge cooling to about 50 deg. The mastic is already hard to the touch. Lot of work, can't even imagine doing without a power turn table, but sure is a lot nicer that 9k out the window. Got video if I can figure out all that is needed I'll post.
Scott
Scott
✔️👍👍
Very nice, Scott.
Scott, for posting video If you have iPhone see below
https://youtu.be/rbl_iaL-JSY
Video
You make it look easy!
Awesome job Scott! Future issues with the AH by owners will be most appreciated of the time and effort you went through and the wonderful writeup of your experiences! Thank YOU!
So during the start of this entire problem Rudy reached out to me and we talked about several items to be addressed. Today I put 16 gallons in the aqua hot. I can't even imagine ever trying to pour in from the radiator cap on top. Rudy recommendation was to service thru the drain valve with a pump using a five gallon bucket to mix coolant and distilled water in. I deviated from his recommendation by using a vacuum pump and pulling coolant it the system from drain valve. Disconnected overflow tank hose for pump. I've done this is the past On other systems and the side benefit is that it sucks the air out first from everywhere. The pex lines above the radiator cap are all full looking. Crazy how it works but nice that It does. You must hold open negative pressure check valve in cap. Ran out of time to run pumps so there still may be some prime issues. Pumps up to 15 psi with no leaks and acts like there is little air left in the system. Still waiting on new cap showing up tomorrow (Amazon) "using forum link, support your forum".Will pump up and check operation then Re vacuum system one last time and top off overflow tank to cold level. Building new 2" exhaust after service.
Scott
Took coach out for a test ride today and was real nice having hot water for the first time. Our aqua hot has been damaged since day one. Will need to turn tempering valve up a little warmer I think but not a big deal. Was one of the biggest projects . Thank you Rudy! Thanks for all the wise words of wisdom.
Scott
Took all the scrap copper tubing to the recycling shop Saturday and they refunded $50 for the scrap copper from the Aquahot. I would of lost that bet. DW was the driving force in recycling it.. I would of tossed that trash. Took all the aluminum window frames from another project too. Left the cash in the garage, neither one of us want to touch that COVID-19 cash. Maybe next week. Lol b^.^d
Scott