Finished the diesel boiler heating system and It all works great! After lots of tinkering and design changes of course.
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Boiler all wired and plumbed. Air intake is black tube on the left. Exhaust is silver tube on the right. It all looks very messy right now, but we'll get to that.
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Used up all the exhaust pipe that came with the heater to get it back and away from the side door and shower as possible. It comes out close to the engine exhaust. I read that some people aim their exhaust at their oil pans. Seems like a great idea if I were to mount the unit in front by engine. But I found this spot was much better location, and the exhaust pipe wouldn't reach the engine, so oh well.
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Our current version of boiler valve control assembly. The problem we kept having is that the control valve in the dashboard is above the highest resting coolant point in the system. So when everything is off, air rises up into the valve assembly. When the pump would kick on, air would end up down into the pump and all the other boiler components. None of that was good. So we installed an automatic air vent to bleed air out of the system when coolant starts flowing.
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We also had to move the check valve onto the engine block where the old coolant line to the stock heater core was originally located on the water pump housing.
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And moved engine coolant feed from the boiler to the back of the engine block. Now, the hot coolant from the boiler will need to travel through the cylinder head, down into the water jacket around the cylinders, and then back out the bottom front of the engine where the pickup hose is located that the circulation pump takes coolant from. All that hurt my brain thinking about it. But it works well, so I can stop thinking about it.
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Anywho, back to the boiler itself. The Eberspacher units are very well made. The control board and all the electrical connections are waterproofed so they can be mounted outside. But this thing was about the most expensive component to the build, and we mounted it down in the gutter! Where it is is mounted it is kind of protected by the front passenger step well, but no way were we taking chances letting it sit down there unprotected all the way. Had some scrap aluminum sheet laying around from when we did the initial demo of the van interior. Cut that up and bent some stuff.
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Welded the seams and bam, got a nice little protection box for the boiler. We put rubber protectors on for around all the stuff going in and out of box to protect from edges. Need something for around the exhaust pipe so it doesn't vibrate, that won't melt. Any suggestions?