Thanks for the info guys. Dad left me so many toolboxes full of machinist bits, tools and assorted I-don't-know-whats that if the local community college had a night class on the subject I'd take it just to find out what everything is for.
With the recent short warm spell I started on getting the Webasto heater installed. Unfortunately the warm weather didn't last.
I bought the heater used off of ebay. It came with a with the fuel pump, mounting plate, hose clamps, 3 short sections of flexible hoses, one each for the combustion air intake, combustion exhaust and hot air exhaust.
The heater was mounted to this metal plate with the rusted studs and nuts. The studs are metric.
I couldn't find exact replacements for the studs but I did find metric bolts sized M6 - 1.00 x 40 at Lowe's. These are the same thread size so just cut the heads off the bolts. Also bought metric nuts to match.
I'll mount the heater on the side step. I've already removed the plastic step.
I think this is the best place for the heater for two reasons. One is it's easy to reach if it needs servicing. In my interior design there will be a cabinet mounted over the heater so it will be protected. A better reason is that this places the heater's air intake in what would be the coldest point in the van. Since cold air sinks this makes the best sense. Credit for this idea goes to Diyvanner.
Cut away the insulation from the mount point.
To mount the heater I'll need to drill holes through the step. This is the bottom view of the heater. Need 4 holes for the mounting studs, two for the inlet and outlet ports and one for the fuel connection.
Start with the stud holes. I know the studs are 6mm in diameter. Use the Pocket Ref to find the next size larger in a drill bit I'll have on hand. Go down the page to 1/4".
Here's what that part of the step looks like from underneath before I begin.
Wanted to use the mounting plate as a hole guide but it won't fit on the step.
Transfer the hole locations to a board then use the board as a drilling guide.
When drilling the holes, don't do them all at once but drill one and insert the threaded stud before moving on to the next. This will help keep everything in line.
Next are the two holes for the exhaust and inlet ports. Use the caliper to get the OD size. It's 22mm.
Use the small chart that came with my hole saw set. The hole saw for 22mm is 7/8".
Each port is dead center between the two closest stud holes.
Use a punch to make a indent at the center point so the drill bit won't wander when I start the hole.
A little coal mining trivia for you. The punch in the above picture is actually a mining bit. Underground mining machines have moving heads covered with a series of these types of bits. It's these bits which do the actual cutting of the coal off the face of the seam. To withstand the extreme abuse these bits are made of specially hardened metal.
It also makes a great punch that will keep a sharp point forever.
Use the hole saw for the two ports.
Use a couple round files to clean up the edges of the holes.
Set the heater in place and mark the location of the fuel inlet.
Measure the fuel inlet and select a drill bit. Notice how small the opening is at the end of the fuel inlet.
This is the connector for the fuel pump which is to be mounted under the van. It has to fit through the hole for the combustion inlet air port. Not going to happen.
Use the jig saw to enlarge the inlet port hole by joining the it with the fuel inlet hole.
This allows the connector to fit through the enlarged hole.
Fit heater into place.
Screw the studs into place to see if they fit. I could lie and say I got it perfect the first time but in actuality the stud holes needed enlarged slightly with the small round file before everything lined up.
If I'd used a larger drill bit on the stud holes then adjustments might not have been needed. There isn't a lot of distance between the stud holes and the port holes so didn't want to take away any more metal than I had to.
Get the supervisor's approval on heater placement.
Remove the heater and rustproof the holes. Wait for the rustproofing to dry.
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