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Old 3 Weeks Ago   #16
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Re: JohnDragonMan's Dispatch/Scudo Micro Camper Conversion

So are you going to be installing Aircon John ??

Its a challenge on any car but one i'm sure you'd be able to pull off.
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Old 3 Weeks Ago   #17
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Quote Originally Posted by AndyRKett View Post
So are you going to be installing Aircon John ??

Its a challenge on any car but one i'm sure you'd be able to pull off.
Thought he had..
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Old 3 Weeks Ago   #18
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Re: JohnDragonMan's Dispatch/Scudo Micro Camper Conversion

Quote Originally Posted by varesecrazy View Post
Thought he had..
Having read back through (which i clearly had not done properly and could have answered my own question) the intention is to install aircon, but he needs to get the aircon wiring sorted out. and seemingly cut a very large hole in the firewall for a second heater blower.
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Old 2 Weeks Ago   #19
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Re: JohnDragonMan's Dispatch/Scudo Micro Camper Conversion

aircon IS going to happen. i have everything to install it, i am already going to replace some things behind the dash, undoing 2 bolts and adding 2 more pipes through the already made holes is going to be easy. the wiring is strait forward. the HVAC controls sends 12v through a single wire that connects first to a 4 pin pressure switch (using 2 of the 4 pins, input and output) on the filter dryer. if the system has an adequate refrigerant charge it allows power to turn on a (pink)relay in the fuse box. that then turns on the compressor clutch.
the radiator fan is turned on using the other 2 pins on the 4 pin pressure switch. these connect to a 2nd low speed fan relay for radiator fans with 2 speeds - mine does not have this. rather than use a resistor i plan to use a PWM motor controller to set a low fan speed. that will be turned on and off using a relay by the 4 pin pressure switch. i will then route the PWM through the rad fans main 5 pin relay through the 5th pin on the relay (the normally closed 87A pin) given the fan motor sits on pin 30 of the relay (if not ill just swap pin 87 and pin 30 around) if the engine gets to hot the relay will work as normal switching the fan from the slow PWM over to the max speed. the relay will keep the 2 speeds completely separate from each other.

the 4 pin pressure switch will detect the pressure change based on how hot the condenser (front
AC radiator) is say if the vehicle is in motion and automatically turn the fan off if enough airflow is already cooling the AC radiator down.


like i say its basic wiring thankfully. the thing i like about this van is that nothing is canbus so it makes life really easy when it comes to wiring. the engine loom is totally separate from the vehicles wiring. only linking the body control module to the ecu using only 2 wires.

also to note that the AC system does not talk to the ECU. the 2ltr diesel engine has more than enough torque at idle to kick over a small AC compressor like what it has.

although retro fitting AC is classed as a big job, i see myself as already 70% complete in the progress of fitting it, and i have not even fit one part of it to the van yet!
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Old 2 Weeks Ago   #20
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Re: JohnDragonMan's Dispatch/Scudo Micro Camper Conversion

I have had many cars I've considered retrofitting A/C to but getting hold of all the associated parts is usually the problem. Being 2005/6 its quite modern to not being using canbus so you're certainly lucky with that! I look forward to seeing the progress on this project, keep it up
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Re: JohnDragonMan's Dispatch/Scudo Micro Camper Conversion

The one thing we wish we have on the van is AC. Insulating the roof with good foil materials helps considerably though not enough in weeks like this.

Have given this a lot of thought, the nuclear option of course getting a different van!

Furlough has reduced long term spending appetite while also offering more time to tinker. Hopefully have cleared the gremlins from this one and at 160,000 or so now want to get 200,000...which will take a while.. So have fitted a 2000W AC true sin inverter under the passenger seat, wired direct to the battery under the floor nearby. It runs the 800W microwave ok with the engine running! It is satisfying how the engine control unit raised the revs from tick over to sustain exactly 12V while the microwave was running.

Have just ordered the lowest power true compressor portable AC unit I could find, 7000 BTU at 750W electric consumption, once here will plumb the hot air pipe out of the van somehow and we will have AC for on the move and when parked on site supply . Will have to monitor battery health closely though pretty sure daytime cruising with it on will be OK, and will consider top up charging if on a site hook up.

So some chunk of spend but transferrable assets which can be used in the home too.
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Old 2 Weeks Ago   #22
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Re: JohnDragonMan's Dispatch/Scudo Micro Camper Conversion

Quote Originally Posted by andydiver View Post
It is satisfying how the engine control unit raised the revs from tick over to sustain exactly 12V
if thats the 2.3L or 3.0L they have some pretty nice alternators on them. we have the iveco daily with the 2.3 (basically a ducato, but with a dedicated chassis) that we just upgraded the alternator on. we also have a 2nd alternator on it that gives out 28v for the leisure battery system.

i still have to work out how i am going to make 48v from my single alternator. ill find a way!

so on the dispatch. well things have happened.





the gearbox somehow fell out. ... ... actually it took quite some getting out. one of the more harder vehicles to remove a gearbox on sadly.

after moving the ABS pump and a few strengthening bars it did come out.

anyhoo the flywheel ended up being a solid flywheel so i had to return my clutch kit and get a different one.
also the crank shaft seal was weeping so i replaced that too.

well used...



still life in it, but the spring plate had gotten very hot and warped the spring tips.



while i was waiting for the parts to come through the post i decided to do some cleaning up. de-rusting and painting.

after a jet wash i was left with this.. nice



and when i removed the strut i found this.. nasty!



thankfully not eaten through!



and if you look here, this is on the inside of the engine bay on the back of the suspension strut location.




just reclaiming sheared off bolts in the best way ever.. Fire!



seen these things in the scrap yard with more left on them.. geez..



just uploading a video now.. all 4K stuff so rendering and uploading takes a while!
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Re: JohnDragonMan's Dispatch/Scudo Micro Camper Conversion

Hi, you need the 48v for the fridge compressor right? So you have one already to use? What kind, that's interesting. How many amps? 12 to 48 step up converters exist, of course, I will keep my eyes open for a decent professional one as I have work with power electronics suppliers if you like.
The problem will be noise.
Thermoelectric peltier would be a lot quieter though not as electrically efficient as a full compressor, and you wouldn't get a freezer compartment very easily, guess you will have thought about that.
For a fridge though perfectly fine. Good ones are still worth paying well over £100 for, pulling around 100W, and will cool a well insulated space very well.
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Old 2 Weeks Ago   #24
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Re: JohnDragonMan's Dispatch/Scudo Micro Camper Conversion

i looked into peltier tech years back, played with it and made some interesting things due to its inefficiency (constant duty cycle and high wattage) though it puts me off them. the compressor i am looking at uses 60 watts and depending on how good you insulate the cool space can remain off for a long time. i can get a DC compressor in most voltages, 12,24,36, and 48 volts. the 48v is because its what the UPS uses.
though not very efficient, i have a DC-DC boost that can take the 12v and make 48v. right up to 40 amps given the 12v side can handle it.i mean whats that.. thats like 160 amps at full draw haha. well given all the solar i am putting on this thing, it should only be needed as a float charge pushing a max of 15 amps into the 48v battery bank. though that would be a hefty 60 amps being drawn from the 12v side. ill have to make it so when the headlights are on it kills the power to the charging system. ill admit that i do not know the alternators current output.


due to "legalities" i had a plan of running a refrigerant line from the low pressure side of the vans (soon to have) aircon system to the fridge system its self with a valve able to isolate the 2 systems. legally speaking then it will be part of the vehicles aircon system that can be "topped up" by a user with no certificate or training needed. i will however also have a top up point on the refrigerator unit in the back too. theres always ways to get around rules and regs.


heres the video:

http://www.youtube.com/watch?v=pkoFXldz_eg

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Old 2 Weeks Ago   #25
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Re: JohnDragonMan's Dispatch/Scudo Micro Camper Conversion

Iím my experience and I do have a fair amount from helping my brother out converting vans from time to time, this is all sounding far too complicated. Fitting aircon is definitely a good idea for a leisure vehicle, makes for a much more comfortable camping trip. But in a micro-camper there is usually only one person. You really donít need a big fridge you can easily install a 12v leisure battery with a split charging circuit and solar panels on the roof, that would provide ample power for a little 12v pettier fridge or something like a waeco compressor fridge, both being designed for camping and both designed to be whisper quiet.

Then you need a bed and some storage for all your camping odds and sods. Some sort of cooker and some sort of sink. Many people in micro campers build little pull out units that you can use beside the van or in an awning. Others build everything into the van. One thing you have yet to encounter is weight and space, if you start trying to fit some huge custom built fridge with external pipework and dc-dc bucks for 48v systems and running lights on 12v systems, having water and cooler and sink and waste water and all your stuff stored as well as camping kit, you have to wonder where you will find space to sleep.

The reason most campers use the same set up of batter, split charge relay, solar, and a cheap little fridge is because they work and they are tried and tested set ups, fitting a dedicated 48v system just to run a fridge is totally unnecessary, complicated, risky from a wiring perspective and using an old UPS is Basically an load of old lead acid batteries joined in series, just take one big lead acid battery and have a more reliable set up.

Obviously you are free to do it however you want but my presumption is you want to get it finished at some point and you want to have something you can use that doesnít weigh as much as the Bismarck and will still accelerate and steer and again a presumption but something that will have space to camp and sleep.

Realistically most people build the bed first and then slot in everything around it, working out what they need as they go, a fridge is not the most important this and shouldnít really be dictating huge modifications just to fit it. If youíre only going out for a night or a couple of nights then youíll rarely need anything more than a little Peltier fridge for some milk and bacon
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Old 2 Weeks Ago   #26
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Re: JohnDragonMan's Dispatch/Scudo Micro Camper Conversion

the 48v was purely down to the UPS i wanted to have a mains 13 amp supply in the van. i have to admit that i am thinking of doing away with it for a smaller 24v 700 watt supply. would half the amp draw.. and be more easy for solar cells to keep a high voltage on. i could still be making 150v from the solar array but because its 24v and not 48v, in low light i will still be making above 24v where as if its a really rainy dark day the array may only produce 50v which would not be enough for a 48v system as most need battery voltage +5 volts so it charges.

most of my lighting is 24v too. the higher the voltage, the less heat is made where voltage drop happens

i could still also work it so that the 24v 700w ups i have would still be the main filter system for power when on electric hook up would be nice if i could find one with a built in AVR so i get a nice stable mains voltage at all times... (dont ask)

well i already burned out my 48v water pump so i guess a 24v conversion would work in my favour.. shame ive already bought and modified a server PSU to be a 48v to 12v (@ 163 amps) voltage converter.

if i could make a sound recording i would let you hear what i sleep with. its a montage of 5 server fans 2 of have really bad bearings. i pretty much sleep through any noise.. and i already have a mini compressor fridge and freezer in my room haha

i have some mental electrical redesigning to do...
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Re: JohnDragonMan's Dispatch/Scudo Micro Camper Conversion

Quote Originally Posted by Dragon Man View Post
the 48v was purely down to the UPS i wanted to have a mains 13 amp supply in the van.
Two things to consider with that is,
1. How long does the UPS last on battery power especially at 13Amps.

From my experience with UPSesses back in the late 90's early 2000's you might get a few minutes to make sure you have time to shut things down, depending on what you run off it. Also unless you are running a washing machine off it, then you're never going to need a 13 amp supply, speaking of which 13 amp at 240 volts is going to draw ~62Amps even at 48volts which is going to draw a lot of heat and kill the batteries very quickly.

2. you can easily fit an inverter for not a lot of money to provide power to anything that does need a 240V supply, but once you start camping its unlikely you will have much that does need a 240v supply. something like a laptop uses about 2amps but then you can get a car charger for most models, virtually everything else these days runs off a 5V usb or only actually uses 12 volts if meant for automotive use.
If using camp sites then you can fit an electrical hook up for £45, pair that with a battery charger and that can charge your leisure battery when parked up or charge off solar.

Its only a little van, so space and weight are going to be major hurdles to over come if you go mad fitting lots of random kit. A leisure battery, Split-charge relay, solar charge controller battery charger and 240v hookup can all be fitted neatly in a corner or under a bed.

While you have the dash out its a great opportunity to put a very large gauge live wire in from the engine battery live through to the back of the van (make it longer than the van so you have spare cable for routing) then fuse it at both ends. This can then be connected up to any second battery you have to charge that, and you can make a very nice well protected and sealed hole in the bulkhead to route it, The fusing at both ends is to prevent any fires if the cable gets damaged in anyway and grounds out on the chassis of the van.

Also look at getting something like these https://www.ebay.co.uk/itm/12V-Car-B...8AAOSwsrBev7Zh

Perfect for powering phone chargers and other USB devices and a good quality socket for anything running off a 12V car lead.
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Re: JohnDragonMan's Dispatch/Scudo Micro Camper Conversion

ahh yes i already have loads of modified USB ports to use. most of those USB ports take a direct 12v input but i really do not like that. the DC dropper circuit is usually not that great and susceptible to external interference causing the 5v on each unit to fluctuate. i will be using a single 40 amp 5v supply and running a dedicated 5v open ring around the whole van. 40 amps is a bit high but the supply i built is pretty efficient and made very over engineered.

note i am not having any windows in this van so it will all be LED lit. i will mostly be using the "JansjŲ" lights found at ikea as they are one of the most efficient LEDs i have come across that takes a direct 5v. (4.9v yet only using 9mA, i am using one now as my main desk light!)
i will also be running a digital RGBNW (SK6812 144led per meter) strip and a strip of 24v high CRI LED strip too too around the roof of the van. to be used when i need lots of light.

i have a plan on using the leisure system to also run external lighting, should i need it. they are all 24v

a lot of the power cables and other things are going to be ran under the van. i am building this not just for camping in but it is also going to be a mobile radio shack so i have to have everything earthed and filtered to reduce all RF noise. all of the wiring will be military grade using a lot of nato plugs and switch. its why i wanted the 48v system again as a lot of my radio gear is made for 48v. however i can modify it all to run lower

ive already made a laptop charger to run from the 48v system, wont take much to convert it to 24v but i will have to changed out all of the filtration capacitors. sigh.

space should not be an issue.. i have it all worked out.. i think...
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Old 2 Days Ago   #29
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Re: JohnDragonMan's Dispatch/Scudo Micro Camper Conversion

well cut a long story short i have had the box out, replaced the flywheel and clutch i have it all together and tried to start it but nothing, just cranking.
so i get the code reader out (hello darkness my old friend, ive come to talk with you again) and sadly i am getting the dreaded P0230 "Fuel Pump Primary Circuit" fault code in the ECU.

this sux.

this sux for a few reasons as i have just put the front back on.
hmm well i tried the red fuel cut out button and sure enough it was tripped so i pressed it in and was damn sure that was going to be the end of my issues. sadly the same fault code persists. however the fuel system now primes when the key is turned.

i must have somehow damaged the wiring on the high pressure fuel pump on the engine. no idea how though as i have not touched any of the engines wiring.

hmm so i need to figure this out :/
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Re: JohnDragonMan's Dispatch/Scudo Micro Camper Conversion

My understanding is the code you have relates to the ecu controlled solenoid part of the fuel pump relay. Wierd because it is now working.
Check crank position sensor.

You will find problem , you just never give up . Good man


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