ExtremeAire Compressor install

[wikid]

I decided to look for a permanent air source for my truck. I thought about a co2 tank, but didn't want the hassle of refilling and finding a place to keep it.

Next up would be an air compressor
I have been running a Puma 12 volt that I keep inside over the rear fenderwell for some time. I was trying to find another place to mount it, but it isn't water proof .
The other option would be to install one under the hood. I wanted to save all the space I could, under the hood, in case I decide to run another battery.

Next thought would be to to mount a compressor exterior. Since there is ample real estate available under the back of the truck, this was a good option. So it would have to be waterproof.

That's where the ExtremeAire compressor comes in. These are really good compressors that have great stats, plus they are waterproof to so many meters, for so long. Perfect
They make a few different models, even 24 volt if needed. The standard compressor is 3.4 hp

Here are the details on this one

ExtremeAire 12 volt Compressor
$414.95

The ExtremeAire Severe Duty Compressor is setting standards for high output compressors. By utilizing a 3/4 horsepower fan cooled motor, overheating is a thing of the past. Designed to fill the largest 4WD tires or the highest-pressure RV tires, this unit can fill tires continuously with no fear of motor burnout. With a 150psi working pressure, you can fill air tanks and run impact wrenches to dismount and mount wheels easily. For clean air in the dirtiest environments, the ExtremeAire uses an oversize UNI-Filter that is crush proof, washable and reusable. All major motorcycle teams use UNI-Filters for Baja and motocross racing. In addition, the fan shaft has a sweeper filter to keep dirt and debris out of the motor and brushes, at the same time, allowing moisture and condensation to escape. The ExtremeAire is permanently lubed with sealed bearings so it can be mounted in any position making installation much easier. Every ExtremeAire utilizes stainless steel fasteners Loctited for a long and trouble free life in the highest vibration applications. Uses for the ExtremeAire include 4WD, RV, Agricultural, Construction, Motorsports, etc. No other 12-volt compressor has the speed, continuous duty cycle, output, pressure rating, and reliability that the ExtremeAire can deliver.

Tech Specs:

- Continuous duty cycle
- 3/4 horsepower motor
- 30-amp draw at 35psi
- 40-amp draw at 150psi
- 4 cfm free flow rate
- 150psi max working pressure
- Can be mounted upside down
- 14" long, 6" wide, 9", tall.

Next choice is the ExtremeAire Magnum
ExtremeAire Magnum
Imagine an ExtremeAire Compressor with TWICE the power and speed, all in a package only 2" longer than the original! Now you can have a continuous 12 volt compressor that will put out 6 CFM free flow and a whopping 2.6 CFM at 100 psi. Nothing in its size, class or price range even comes close! The ExtremeAire Magnum utilizes a 1.5 HP fan cooled motor and longer piston stroke to make the impossible possible. The Magnum has all the key features of the original ExtremeAire such as superior filtering, stainless steel hardware, heat dissipation cylinder coating and powder coated filter housing and fan shroud. Plus it can be mounted in any angle or position, even upside down! Sealed bearings mean no servicing or lubrication is necessary. Uses include filling tires, running air tools, air bags, lockers, train horns, etc. It is the perfect unit for jobsite chores or ranch duties. Since the unit is totally sealed from the elements, you can mount it under your truck on the frame rail so valuable storage space is preserved.

Specs:
-1.5 HP Motor
-95 amps @ 12.5 Volts DC
-Continuous Duty @ 150 psi
-6 CFM @ 0 psi
-2.6 CFM @ 100 psi
-Weight: 20 lbs.
-Dimensions: 16" long x 6" wide x 9.5" tall

My final decision was to go for the Magnum. I wanted to put the worst case scenario in as far as size goes, Since it was only 2" longer, it still will fit where I want to go.

Here's what brown brought me


Next post I will go through the mounting/install

 

[wikid]

Along with these items pictures were 25Ft high pressure reinforced brake/air line. 25 ft black and red 4 awg 2 quick disconnects front and back . a bunch of quick snap air fittings. a head pressure bleed off switch, so the cylinder unloads for start up. air regulator solenoid. 80 waterproof circuit breaker , 100 waterproof relay and various terminals heat shrink.

I got all of this equipment at Extreme outback Products . George is really helpful and knowledgeable
http://www.extremeoutback.com/


I made a plan on where I wanted it, so I needed to build a crossmember to make it work
Here's what I came up with








It fits perfectly between the frame rails attaching to 3 threaded holes on the frame each side. It doesn't hang below, the rails at all. I will make a skid plate to protect it and put heat shields under the exhaust pipe. I intentionally mounted the heavier compressor on the passenger side, to not make the FJ lean any worse.
Its now painted and will be install tomorrow. I will take more pictures of the electrical, air routing when it's done .

 

[wikid]

Part 2 is complete. After test fitting the bracket some adjustments had to be made. I actually wheeled with the bracket in place yesterday. The adjustment I made was making sure there was a separation between the compressor frame and the body above it. I thought I allowed enough in the original fabrication, but after pulling the bracket, today I saw rub marks on the body above the frame so now it is spaced more.

The compressor and tank were mounted , pressure switch plumbed in, blow of valve attached and everything from the compressor to the tank is now complete.

The hard stuff is done.
Next phase is plumbing the air fittings and running all the electrical. I hope to have it running this week and do some testing.

The entire unit together weighs 47# . I'm not sure what a CO2 set up weighs full, but if someone could give me the weight, that will be a good comparison.

Here are some pics mounted

 

[wikid]

I made more progress today. Air lines in place, on opposite corners of the truck, 4 awg ran to the engine compartment, relay mounted on the cross member over the pan hard bar. Everything on the rear is now wired and ready to go. Still need to punch holes in the bumpers for the air chucks, and wire in the 80 circuit breaker, under the hood and I can start pumping air

 

[BrianTN]

Looks good. I'm in the middle of installing OBA on my truck as well.

 

[wikid]

All ready to go. I aired up a 35" General Grabber on 17" rim from 0 to 42 PSI, in 3 minutes flat

 

[fishEH]

Do you have any rubber feet for the compressor to mount on? Hard mounted compressors tend to rattle themselves to death.

 

[wikid]

No rubber mounts I was told by Extreme Outback it isn't necessary. I ran it for about 30 minutes without an rattling. It seems pretty smooth

 

[Wh1t3nukle]

I like it. Very clean install you have going. Glad to see you plan on some heat protection. Will that be on the exhaust or on the comp? Putting off the comp would be suitable as it would also act as keeping some of the elements off of it.

What size are the bolts used b/t the comp and your frame? Also what size are they b/t your frame and the rig frame?

Just curious, any reason you picked this section to post over this one? http://www.expeditionportal.com/forum/forums/29-General-Vehicle-Modifications

 

[wikid]

I like it. Very clean install you have going. Glad to see you plan on some heat protection. Will that be on the exhaust or on the comp? Putting off the comp would be suitable as it would also act as keeping some of the elements off of it.

What size are the bolts used b/t the comp and your frame? Also what size are they b/t your frame and the rig frame?

Just curious, any reason you picked this section to post over this one? http://www.expeditionportal.com/forum/forums/29-General-Vehicle-Modifications

Thank you. I have had this thought for a few months. I am happy with the execution .
I think I will make some sort of skid below the entire area. Nothing to elaborate, but at least to keep some of the heavy muck off of it. Then a small outer shield for separation between the skid and the exhaust. A double layer so to speak

The frame had 3 threaded unused holes, that were perfect for mounting the cross member to. The hardest part was centering them , with the cross member in place . They are 8MM x 1.25 thread. I just happened to have some SS bolts laying around, so I used those. I decided to keep it all fairly standard to the FJ and used 8mm x 1.25 bolts for mounting the tank and compressor to the cross member. I actually welded the bolts through the back side of the new cross member and used washers and nylocks to secure it. I just figured the nylocks, would keep it from any vibration issues. This keeps my tool selection the same, throughout the truck.

As far as where I posted it . I guess I could have posted it in a different area. I was not sure where I should place the emphasis. If it makes more sense, maybe one of the Moderators could move it to the other section.

On another note .

I went to a local IH8Mud (Copper State Cruiser), meeting last night where we did a compressor shoot out. Lots of guys around here use a Puma 12 volt with tank that usually ends up in the rear cargo area. I actually replaced my Puma with the ExtremeAire. its a real good solution for the money at about ~$225.00. I still like mine, but I wanted a solution that didn't take up cargo real estate, so that is where I am at now.

We discharged all of my tires to ZERO and did a comparison between the Puma and ExtremeAire from a zero PSI state. Hooked up and hit the power button at the same time.
The Puma filled my 35" General Grabber from zero to 24 psi in 3 minutes. The ExtremeAire went from 0 to 34.5 psi , in the same 3 minutes. My thought is I can fill 4 tires from 15 psi to 40psi in about 10 minutes which is about 30% faster than the Puma . Its also 100% duty cycle and has great flow numbers, for running air tools . Plus , it is out of site and not taking up valuable cargo space .

 

[Raul B]

great post......

 

[wikid]

Just an update on usage.
Today, I needed to pull all 4 of my wheel/tires . I decided to use the compressor with an impact . it would cycle on once throughout each wheel , but still kept enough pressure to easily remove 6 lugs at a time. I did this to pull the wheel spacers, so immediately after pulling the wheel I pulled the spacer. Another 6 lugs. i never turned my truck on for the entire set and it ran fine.
I also tried a air drill, but the instructions specify that it needs between a 6 -30 gallon tank to be affective. It would drain and run slower after about 30 seconds of drilling, but would work if you weren't in too much of a hurry . Bottom line I think air ratchets and impacts would work just fine with this system, but some of the air hog stuff wouldn't because of the lack of stored volume.

Luckily, I have a Odyssey 2150 battery that seems to have almost endless power. If I were on the trail , I would definitely run the truck for this exercise.

 

[Jr_Explorer]

Next choice is the ExtremeAire Magnum

Specs:
-1.5 HP Motor
-95 amps @ 12.5 Volts DC

... 4 awg ran to the engine compartment, relay mounted on the cross member over the pan hard bar.
... and wire in the 80 circuit breaker

Houston. We have a problem. If the compressor draws a max of 95 amps shouldn't you have a circuit breaker larger than that for some margin? And I did a quick Google search and found the link below. 4 AWG wire "seemed" a bit light for that kind of current and it looks like you are right on the verge of maybe wanting to run 2 AWG. Just food for thought. I'll let soe of the more electrical savy types chime in and let me know if I'm way off base here.

http://www.westmarine.com/webapp/wc...w?storeId=11151&page=Marine-Wire#.UsBWDGRDt8Y

Edited to add this cool wire calculator link:
http://circuitcalculator.com/wordpress/2007/09/20/wire-parameter-calculator/

 

[wikid]

Originally I thought the same thing.
After deciding on the system, George, from ExtremeAire explained to me that the 95 amp draw was incorrect, since we are using a pressure relief valve, that unloads the head pressure for start up. The 95 amps was the absolute extreme , without a pressure relief. I will be doing a actual amp draw test, for the system in use. So far , even with airing up 8 tires and using my air wrench for extended length of time, it hasn't even come close to blowing the breaker. The actually amp draw is probably closer to 40 ish .

All of this was set up with Technical advice from ExtremeAire and is commonly configured this way. The more important points they were concerned with, were that an actual ground wire was ran back to the source, instead of just grounding to the frame , which is what I have done .

Good point. I probably should have explained that, during the process, since I also provided the link for anyone interested in the system .

Thank you for the link to the wire guide. That will be useful and save me from hunting

 

[Jr_Explorer]

Originally I thought the same thing.
After deciding on the system, George, from ExtremeAire explained to me that the 95 amp draw was incorrect,

Ah... Yeah... Their specs should read "Starting Load Under Pressure". I can see THAT being extreme. Thanks for the clarification as things just weren't adding up. Please do report actual running load as that will be interesting. Thanks for the write-up.