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Adding (back)air conditioner

AnEv942
Nomad
Nomad
After few years of not having Air conditioner we've decided to put it back. Couple of years ago we had decided not to replace when we rebuilt the roof. Only used once or twice a year and the expense. Seems though that once or twice a years getting rougher and more intolerable. (more than we remember when we HAD A/C).

Due to the space being partially absorbed by larger solar panel that was moved away from existing vent, and replacement antenna with the wingman feature and possible solar addition in the works, opted for the Brisk ll due to its small foot print 27 5/8" x 29 5/8". A bit taller than Id like but it will fit.

Couple of tasks getting ready:



One was the antenna. It was always close but the new wingman feature no way even the smaller ac will it work, almost touches the vent let alone AC.



Spent good part of the day reworking the antenna- flipping the head to other side of arms. Worth the effort as this antenna works well (and still does after 'fixing'). May put a tennis ball or something-use the radio ant as a brush guard.



Spent remainder of day removing the Fan-Tastic Vent, well actually cleaning the roof. Pencil is where guesstimated AC will be. Once AC arrives and I get some real placement dimension I can remount the FTV, cutting another hole. Hopefully directly in front to keep in center, more likely off to side. However...


New/now
Contacting Fan-Tastic tomorrow- Im a bit concerned with the lid. It has yellowed terribly, like brittle looking to the point I wont remount until I replace lid. 3 years old, I dont know if thats warrantied or not.

AC is supposed to show Wednesday. Then I can locate placement for fan. I need to run 12v for fan while AC hole is open. If needed I could just cut thru ceiling and not roof to get wiring done between the 2 vent holes. Remount the fan later. To be done. Just chompin at the bit waiting on parts.
8/17 Update all photos
01 Ford F250 4x4 DRW Diesel, 01 Elkhorn 9U
Our camper projects page http://www.ourelkhorn.itgo.com
17 REPLIES 17

dadwolf2
Explorer
Explorer
deleted!
2005 Dodge Ram 2500 CTD,4X4,NV5600
2014 Adventurer 86FB

AnEv942
Nomad
Nomad
Replacement lid from Fan-Tastic Vent showed up.

They also sent a new lift arm assembly, not sure why but I went ahead and swapped it out.

New lid is smoke, wasn't sure what color I was getting. Its nice, can see thru it, and lets light thru, camera doesn't like it.


Ended up with 12" between the 2 14" holes. Forgot how much fun the Dicor self leveling caulk is. While I had the 2 holes open I should have prerun wire across the roof for when/if planned solar panel addition happens, hindsight.


More than likely I'm pulling off the shroud today, painting the AC base white and some of the metal bits exposed behind grill -it really stands out. Maybe it wont look as tall as it is but the black bugs me. Replace the shroud screws with stainless, slow the rust down a bit. Piddly stuff.


Edit:

New vent lid. Removed the shroud and paint most of the sheet metal bits and screws with zinc, painted what showed thru grill black (not condenser). Painted the base white.

I also sealed the hole that leads inside where wires pass. The hole is in one top of the plastic fan housing, looks like half a tube of sealant was squirted in but still didn't seal top of hole. From inside (with shroud off) I could see light. ? Where its at probably only would have leaked while driving in hard rain.


White base just looks better to me, less visible to my eye anyway. Now were done.
01 Ford F250 4x4 DRW Diesel, 01 Elkhorn 9U
Our camper projects page http://www.ourelkhorn.itgo.com

jmckelvy
Explorer
Explorer
Nice neat work! Good job. You will enjoy the AC especially if you ever venture down to our neck of the woods.
06 RAM 3500,Dually,CTD,Auto(ATS Stage 1),QC,4X4,PacBrake,Spyntec Freespin Hubs,60 Gal Titan Tank,EFI Live, Line-X,Torklifts and SuperHitch,Fastguns
2013 Arctic Fox 990, 275 Watts Solar, 2 Grp 31 AGMs
US Navy 1964-1968, 2-Tour Vietnam Vet

dakonthemountai
Explorer
Explorer
Yay!!! Congratulations on a job well done! Functional and good looking too! I love it when a project is completed and working. Nothing like looking back and thinking.. "That's what I wanted to do.... and I DID it!" ๐Ÿ™‚

Cheers!

Dak
2018 GMC Denali "Extreme" and 23' EVO 2050T Travel Trailer
Escapee member #224325-Since 1992

AnEv942
Nomad
Nomad
Just concluding this. Campers buttoned up. Nice to do a project cause I want to.

Got the vent rewired. Cut interior sleeve to fit, bit tight as it slips between the fan control plate and exterior sleeve that drops down. Theres only about a 1/16+ gap sleeve slides between. With the vent at an angle in relation to interior ceiling takes abit to get started but otherwise slipped right in.

Slides not completely out, but a bit awkward for me to reach the knob because of slide floor in front of the refer.


Trimmed the ceiling panel trim. Started picking up the camper. Pretty happy, got AC back and keep our vent...


Margaret came out, shes is really happy with the new AC as the heat really bothers her. She was impressed with the vent over the fridge, "This will be nice, its better over to the side as its always dark on this side", then steps up on the slide floor in front of the fridge like shes been doing it forever, opens the vent. "Perfect" She says and closes the vent. "Do you need any help putting your tools away?" Uhh, no I got it, thanks. And she goes back to the house.

Standing there for a minute, I step up on the slide floor and reach for the vent...huh.
01 Ford F250 4x4 DRW Diesel, 01 Elkhorn 9U
Our camper projects page http://www.ourelkhorn.itgo.com

AnEv942
Nomad
Nomad
2 days later, Record heat, been a bit slow to button up, hit 104ยฐ here on the central coast other day.



Yesterday hi 80s. Moved the slide out. Vent is going between AC and fridge. Wish the camper was a clean as looks in pic-its a disaster.

Originally I was going to place as close as possible to AC, decided to leave as much material as practical between and still have vent fully exposed in front of refer when slide out.



It literally took me 3 hours to get to this point. Working blind from roof getting the 14" hole centered between the rafters. Framing the hole with 1x s, placement pretty critical as the space between rafter is ~15 1/2". Drilling exploratory holes, locate rafters, drill a bit more, cut holes larger, etc till have square hole centered.

As the inside ceiling is flat and roof slopes to outside wall, cut the front and back to match spacing/angle between. Worked to my advantage as I could slide pieces into the larger side, then slide back centering. Cut a little over 20" long, diagonal of hole. Glue and stapled blocks on end to have attachment place for side pieces.

Liberally applied glue to all surface thats touched something, add some more glue and stapled to rafters. Ill staple roof to box once sides on.



Sides cut and stapled to front and back with even more glue. I almost stapled the side piece on forgetting to pull the 12v feed wire. Removed, drill a hole, retrieved the wires and then stapled. Good grief. Then stapled perimeter of roof to box. Drill holes thru ceiling panel in corners to get placement.




Removed the support I had forcing the ceiling panels against the rafters. Scribed the hole.



Whoo whoo we got light. I hadn't realized when planning this the angled space between the roof and ceiling. Hopefully not an issue with fitting the inside trim sleeve. I will need to cut a bit both in height and angle.


Surprisingly its square to the ceiling panel trim it will butt against-Didn't have any control over that as rafters placed.
Squirted some more glue between ceiling panel and rafter, staple ceiling to box with 1/2" crown stapler.

Was getting late but decided to set the vent in hole. Good thing seriously wet fog last night. Im waiting for it to burn off before I get back on the roof this morning. Removing the lid I had pre-drill all the holes, laid butyl tape on the flange and screwed it down. As it got late I didn't trim the butyl, first this I want to do. Hoping its not problem trimming after setting over night.



Almost done, few details, installing the fan control & wire, trimming the interior sleeve/garnish. Get the butyl trimmed, Ill Dicor flange & screws when it looks like done oozing. Trim the ceiling panel trim to fit. Probably add some finished pics...just waiting for the roof to dry. Typical 65ยฐ high fog coastal day.
01 Ford F250 4x4 DRW Diesel, 01 Elkhorn 9U
Our camper projects page http://www.ourelkhorn.itgo.com

AnEv942
Nomad
Nomad
Unit arrived few days ago-tiny footprint but tall. Because it's so short looks even taller, I think our old one was about 10" this is 12 5/8", thats Tall. But it fits the available space we have, considerable less cost and at 72#, especially after turning it on yesterday pretty stoked. More stoked thats its done.

I didn't get a picture on the roof, it was too hot to uncover and get up there. Hid out in the shop all day. But reminds me the old air scoops they use to run on Vdubs, shark fin.

edit roof pics added at end



One of the 'pre install items.
Not sure it was needed, probably non issue but I just didn't like the 32 screw holes from vent that would end up 1/2" from perimeter of AC gasket. So I wrapped with some 4" eterna bond tape. Local RV sells by the foot. Split into 2" strips for end and sides, cut front to 3" center taper to 2" on ends. Overlapped from bottom up. Thinking slight edge might help divert nightly fog from running and setting against the AC gasket. Again probably unneeded.
After AC done Im cutting a new hole to reinstall the Fan-Tastic Vent beside AC.


Last 'pre was reconnecting stub wire from ceiling AC pre wire connection box. Drilled a new hole to route closer to box of AC.



'Accidentally' got it on the roof yesterday. I was in the middle of loading camper and the AC stuff to take to friends. But getting the AC box into the camper it became apparent that wasn't going to happen. I had dead lifted from ground and sat on the patio railing. If I can lift it and carry into the camper it would be easier to walk up a ladder..so I tried not knowing if I could. Lifted from the railing onto 6', got on the 8' drug it over, then tilted the box toward roof, one shove and it was up there. I was amazed-been setting on it for 3 days.


And installed.





Not overly impressed with the way the inside unit interfaces, just different, primarily that is uses the vent hole thru roof and the ceiling as part of the distribution box. It uses a foam block that divides the 14" hole. At least Im use to an interior metal box thats is fed by duct between the top & inside units. Works, part of the cost reduction I assume. I sealed & lined the 14" (wood) vent hole with aluminum tape. As this will only be used infrequently maybe a couple of times a year not really that concerned. Otherwise if used a lot easy enough to cut a piece of sheet, box and duct.


Pretty easy install once the unit on roof. Couple of snafus, mostly operator error. The whole time I was getting ready I had the orientation of inside shroud 180ยฐ off. With the divider and inside metal in place, umm Im scratching my head 'why is the 110V on the wrong side'-looking thru instructions no mention of how to get thru divider to 110v box to connect, hey that 'front' is... :S Dohh...

Took it apart, pulled and rerun my new prewire that I had rerouted to what I thought was closer back thru original hole in vent hole.

Second was my new clicker inch pound wrench. It doesn't audibly click, at least at lower settings lower than 50. Fortunately I started out at 20, I realized this seems awfully tight and not clicking and took to shop. Figured out its not audible, handle kind flops. Rechecked the ac and I was up to 35 before I noted the handle indication. Rerun to 45 inch pounds.

Other than that pretty quick. Bolted down, I connected the wiring. I had pulled the inside ceiling panel trim. Im cutting to fit so inside shroud sets flush against ceiling.

Install the shroud and turned on. Surprised, It is way quieter that our old coleman. Walked in the house to get a cup of coffee, back to the camper I open the door... wow.



Dropped from 82ยฐ to 67ยฐ in time it took to go get a cup. The 80ยฐ is inside refer. Pretty cool, literally, the air output on our old unit was never as cold. Though only 82ยฐ I hope this is indication of what we might expect. Margaret is excited.

Have 10" between the AC and solar panel so shouldn't see any shading, I can walk by. I don't think for most, due to its height the Brisk ll a good choice on a TC but its a nice unit and only viable option in our case.

Last detail was the knobs. The have a little bump that is indicator. Hard to tell which way its pointing once knob is turned.

Used a small ball end on Dremel, filled with paint-that'll work.
Other than getting AC up on the roof, only real work is cleaning old vent hole if replacing a vent.




Next reinstall the Vent beside the AC.
01 Ford F250 4x4 DRW Diesel, 01 Elkhorn 9U
Our camper projects page http://www.ourelkhorn.itgo.com

AnEv942
Nomad
Nomad
Well as you cant buy much for a dime nowadays if we tag up we'll splurge on some dounuts and a cup to dunk em in ๐Ÿ™‚

Inside half of AC arrived..hope the 80# box survives the trip better.
Looked like it was drop kicked into the truck, hmm, appears fine though. Ill be inspecting top unit pretty good. Watched a video fella installed one, apparently pan was bent but didnt note until after installed-retailer wouldnt warranty. Thats gotta hurt..
01 Ford F250 4x4 DRW Diesel, 01 Elkhorn 9U
Our camper projects page http://www.ourelkhorn.itgo.com

dakonthemountai
Explorer
Explorer
AnEv942 wrote:
KUDOS to Fan-Tastic Vent!
Just got off the phone with Fan-Tastic Vent. As I didnt know about the lid and sunburning if covered but they are shipping me a new lid! Not even a hesitation. Just pay shipping, oh wait its under 4 years -we pick up the shipping. Hokey smoke.

What can you say when a company responds like that. Im just amazed.


Cool! That's been my experiences with them over the many years I've had their products. So. Do you owe me dimes or donuts? ๐Ÿ˜‰

Dak
2018 GMC Denali "Extreme" and 23' EVO 2050T Travel Trailer
Escapee member #224325-Since 1992

Stars101
Explorer
Explorer
Oh, phew! I was concerned for a moment LOL!

AnEv942
Nomad
Nomad
Stars101 wrote:
Sunburning if covered? I've never heard of this. Do you mean that it gets too hot under a tarp or cover? That's a nugget I need to file away.

Ha...no I meant if sunburning covered by warranty.
01 Ford F250 4x4 DRW Diesel, 01 Elkhorn 9U
Our camper projects page http://www.ourelkhorn.itgo.com

AnEv942
Nomad
Nomad
Removing the sealant, both butyl and dicor self leveling caulk. Mostly time and patience, perseverance. Take into consideration that it wont be enjoyable and it wont be over quickly and trudge thru it. The sealant is the chore, the putty or butyl tape not too bad.

Separating the vent was suprisingly more difficult, ours is/was a Fantastic which has plastic flange that I didnt want to crack. Or cut my roof. I had installed mine so it was a bit neater than factory (not as piled up). Laid some towels on roof to protect. I was able to see where screws were and push screwdriver thru to remove.

Slowly going around and around pushing plastic putty knives under till I got perimeter dicor cut, then going round again going deeper to cut the butyl tap, then going round again insert knifes but then slide a THIN small pry bar on top to lever-slowly pry apart but almost not noticeable, insert another putty so it didnt restick, move down a bit, repeat, round & round till it finally started lifting. Spent a good hour just getting separated.

Getting the dicor off EPDM roof, carefully pushing plastic knife cut bulk off, then used thumb to push, roll and pull off. I used acetone primarily when I got it pretty clean, I did use paint thinner as that actually works better but BAD for the EPDM. Tried to confine to sealant area, lots of clean rags lightly dampened with thinner to scrub off sealant then light wipe with acetone. Avoid getting the rubber wet.

If I never see the back side of a sealed app on my roof as long as I live I will not be unhappy. Its a chore on the rubber roofs. Single most reason that reinstalling AC was made with great reluctance and only reason I almost decided not to. But its done. If only 10% of the project its still by far the real chore in my opinion.

On a fiberglass, painted aluminum or plastic roofs after cutting off bulk you could just wash with paint thinner (acetone will remove paint, dissolve plastics not sure but I wouldn't use on fiberglass or gel). Paint thinner is fairly mild solvent but not on EPDM, can cause it to soften & swell. All that said I might have spent another hour maybe 1 1/2 cleaning. But as you might glean...I hate it, my rant. Course because the AC uses a gasket and not sealed cleaning more critical verses reapplying a sealed fixture.

Cant tell you how glad Thats done...if it took another 2 weeks to reinstall the AC, still Im on the downhill side IMO, the rest is gravy.
01 Ford F250 4x4 DRW Diesel, 01 Elkhorn 9U
Our camper projects page http://www.ourelkhorn.itgo.com

dadwolf2
Explorer
Explorer
What / how did you remove the gobs of sealant around the vent? What seemed to work best for you?
2005 Dodge Ram 2500 CTD,4X4,NV5600
2014 Adventurer 86FB

Stars101
Explorer
Explorer
Sunburning if covered? I've never heard of this. Do you mean that it gets too hot under a tarp or cover? That's a nugget I need to file away.