Tuesday, August 30, 2011

Trip went well

Well I completed an 1000-mile round trip journey into the hot land and back. It went great! Everything worked more or less as planned.

The cab stayed nice and cool, and no coolant leaks or coolant smell, since I bypassed the heater core. Transmission ran great, engine ran great, all was well. I went down the coast, saw some beautiful country, stopped along the way at campgrounds on the cheap, toured around in LA, did my obligations there, and came back. It was a joy being at home no matter where I was.

I bought two new tires for the front, and moved the front tires onto the rear, replacing the two balding ones. So for the first time in the 4 years I've owned this van, I'm driving on 6 GOOD tires now.

I learned a few things. First of all, I'd overinflated my front tires, so my handling was kind of dodgy; it felt like the van was weaving all over the road whenever I went over any kind of bump or hill. I think my rear springs are sagging too; will have to find out what's involved in putting a new leaf in there. Bled a few pounds out of front tires and that improved the handling a bit. Also, I carried way too much fuel. There are a couple biodiesel fueling stops along the way, and they're very nice, and open convenient hours, so I could have done it all just by filling up along the way. The 5 gals of spare fuel I brought just added weight I didn't need, so I didn't use it on the way back.

Also, I know now what my MPG is. 10. Yes, 10. I get 10MPG. And biodiesel is like $4.60 up here. So it was not a cheap trip. Granted, that 10MPG includes winding down the coastal highway 1 at an average speed of 40MPH, so it's not really a freeway measurement. I took the freeway on the way back and I'm sure that was much better mileage.

And, in 100-degree heat, the fan and vent is useless. My insulation certainly works great-- it's 20-30 degrees cooler in the box than in the cab, for example-- but once the heat picks up in the afternoon, the fan is just moving the hot air around. At night, it can take an hour or two of running the fan full-on, before the interior finally cools down. And even with the sun shining brightly during the day, there's not enough sun to fully recharge the batteries from running the fan at full 4A blast at night. I think if I had to spend more time in that kind of hot climate, I'd have to say, nevermind the solar panels, just park in the shade as much as possible.

When I got back, it was time for an oil change (I do mine every 3,000 miles or so). I know, I should have done an oil change BEFORE driving 1000 miles through the heat, but I'd just changed it and it wasn't quite ready to be changed yet. So I waited until it'd been 3,500 miles, and the oil was FILTHY. Just disgusting, much worse than last time I changed it. Black, nasty oil. That'd mean carbon. Also, it was MORE viscous than clean oil, a lot more viscous. Biodiesel blowby? Maybe my rings are going, or my valve guides.

Another very odd thing: my air filter is filthy, but it's filthy with what a brown discoloration that looks and smells like biodiesel! It looks soaked. I'll have to get a postal scale and weigh it versus a clean one to see how much stuff is actually in there. But, how is biodiesel getting into my INTAKE air? The only thing I can think of is that perhaps, when I start up the engine cold in the mornings, and I always get a huge cloud of white smoke coming out, sometimes the wind blows some of that into my intake and it gets caught in the filter over time. Not sure though; that one is a puzzler.

Friday, August 5, 2011

The work gets easier

Doing work on my van has become an absolute joy. I love it. I know what I'm doing now, and that makes it fun.

I finally got my cooling system squared away. I did a bunch of research and realized I'd been misreading the test strips. Turns out I desperately need to replenish my SCA's, so I'm in the process of calculating exactly how much I need to add and will add it.

I think my heater core is pluggged up and possibly leaking too, but getting to it requires dismantling the entire dashboard, steering column, and ignition lock, so I just bypassed the heater. Bent the supply hose around double into a U and connected it to the return. Done. On this vehicle, the heater core is ALWAYS live, no matter whether the blend door is in the hot or cold position! So by disconnecting it, it'll probably stay a little cooler in here on the hot drive south.

My coolant was in what looked to me like perfect condition. I also checked the flow of my transmission cooler and it is excellent. I did find a bit of sand (yes, sand) in the coolant, but it wasn't magnetic, so I'm not worried about it. A friend said that it might be sand leftover from the cast iron block stamping! Imagine that.

The squeaking/parping sound may have been caused by transmission fluid dripping onto my drive belt and more or less ruining it. I cleaned it off good with rubbing alcohol and the squeak stopped. But I also did the transmission cooler line check, so perhaps the noise was coming from the trans after all. No matter; it's gone now either way.

Well that's it, I'm ready to drive. I might replace two balding rear tires first before this trip, depending on whether I can afford it. I'd like to bleed my brakes but that's easy, and top up my differential which is seeping. I probably should do an oil change, but I'm not really due for one until AFTER the trip, so I'll probably wait on that. I'm sure by then my air filter will be toast. This turbo breathes a lot of air, and riving around on dirt roads is rough on my air filters.

Wednesday, August 3, 2011

Moore's Law and capitalism

I've said for many years that there is only one thing that capitalism does better than anything else, and that is: make cheap gadgets.

I'm thinking about this as I'm sitting here, I'm legally considered homeless, but I have no less than 7 microprocessors in here! Most of which were cheap or free. I also have at least as many embedded microcontrollers too, and another half-dozen sitting in a drawer as chips ready to be placed into some project or another.

I'm part of a technologically-advanced underclass. I'm told that in China there are huge masses of deeply poor people running around with tons of microprocessor gadgets as well.

Moore's Law keeps marching on; computers keep getting more powerful and cheaper every year. As for other things like food, medical care, etc, even energy, not so much.

There are some interesting developments attempting to apply Moore's Law to problems like energy (i.e. solar energy, battery-driven cars), but they're haven't become quite the self-accelerating spiral that the semiconductor and consumer electronics industries are yet.

Thursday, July 28, 2011

Showers? What showers?

Over the past month, I've tried getting by with little to no showers, but washing myself down with a washcloth every night instead. It is working out very well. I feel cleaner, and I don't have to be near a gym all the time.

I can also do rather gross, sweaty, nasty mechanical work too, freely and without worry, knowing that at the end of the day I will be clean, and I can do the work not necessary within a short walk from a shower.

On a financial note, I made a profit this month, and was very pleasantly surprised by that! I managed to make back the loss that I suffered last month, so I'm basically back to just breaking even again. But I did it with only two relatively small projects, and both of them very enjoyable (though not terribly well-paying). So I'm happy about that.

Fighting off a summer flu now (the worst kind), and camped out in a lovely, quiet, but still centrally-located spot which is quickly becoming one of my favorites. Quiet is so important to me. It's really all I want, is quiet.

I'm not looking forward to driving down the coast next month. I'd really rather drive UP the coast, up north, that's where I want to be! Maybe later in the month I'll do that, if money permits. But for now I am committed to this trip down south, so we'll see. A lot of research was required to locate biodiesel stations along the way, but I think I have a path mapped out. Still, I'm going to take along an extra 15 gallons of fuel, just to be sure. I could always put dead dinosaurs in here if I really got stuck, but the fun is trying to do the trip without having to resort to that.

Saturday, July 23, 2011

More cleanups

I organized my storage so I could get to my files more easily, then I organized some of those files, now that I can get to them! And I found the receipt for my "biodiesel" pump. Turns out, I bought the wrong thing, it was NOT rated for biodiesel, just rotary oil pump. So now I'm going to sell the thing, once I finish cleaning it off.

I found a new biodiesel-capable pump online for $50, which is less than I paid for the incorrect one several years ago.

I also replaced a badly rusted bolt and washers on, my driver's mirror. Total cost $1.07, which is much better than the $200 that Ford wants to charge me for a new mirror assembly! The arm for mirror is rusted, so I will need to change it out eventually, but I just bought myself another year if I want to. And I might be able to find something aftermarket for a reasonable price.

I found the source of that whining sound at engine speed before the van warms up: it's either the transmission or torque converter. And the source of that "parp-parp-parp" sound that is like a loose bearing somewhere: it's the reverse gear on the transmission. The sound only happens in reverse, and for a short time after the vehicle has been in reverse, and only when the engine is fully warmed up.

My next significant mission is to check the transmission cooler/pump flow rate (for obstruction or other problems), and to drain all the coolant and replace it with new.

Also, a friend has found an interesting single-tank, electric-heated SVO system for Mercedes, which maybe could be adapted to my Ford PowerStroke. If so, and if I feel like trying another fuel experiment, I'd love to be able to run on straight veggie oil instead of dealing with biodiesel. But it may take me months of careful investigation before I'll even know whether I want to do that.

Sunday, July 10, 2011

Solar electrical notes, lots of them

Long post, originally intended as an answer to a vandweller mailing list post. It was too long, so I decided to put it here instead.

I started vandwelling with just a vague notion that I rely on electricity and internet a lot for my work, so I knew I needed "lots" of electricity. I overdesigned and underdesigned as a result.

After some years of thrashing around, I found out that the solution was to actually MEASURE stuff. Like, with an ammeter. And then do some math. Then I can make useful decisions to make everything work right.

For example, laptops suck for vandwelling, IMHO, especially if you rely on them a lot. Mine uses 2-5amps at 12v! When I started out in my van, I was also stupid enough to hook mine up to a large-screen monitor which required an inverter, for a year. The inverter was inefficient and used up current itself, as well as having somewhat low efficiency in converting 110v to 12v and then the monitor's own power supply converting it back to whatever the monitor used inside (probably 12v and 5v and 24v). Not smart.

What I learned is that netbooks and smartphones are nearly ideal for vandwelling. They hardly use any electricity and can be easily charged up off of your alternator (if you drive a lot) or a modest-size, relatively-inexpensive solar panel or genset and house batteries (if you stay local a lot).

If you use a 12v netbook, DEFINITELY get a car-adapter for it. Your batteries do not put out 12v-- they put out whatever they have left in them plus whatever is being used to charge them. Your alternator or solar charger or genset or whatever will shove 14V or more at your netbook. Mine took the abuse valiantly (probably has its own internal 12v regulator) but started making buzzing sounds when running in high-voltage situations. I got a DC-DC converter and all is well. When your batteries are low, they'll put out less than 12v. Get a DC-DC car charger/converter/adapter for the netbook that'll give it a nice regulated 12v no matter what.

Likewise, electric refrigerators are GREAT for a solar-based van setup, if you buy the super-efficient Danfoss (TruckFridge) models that only need 2A to run and only run a few hours a day, and keep your van and refrigerator insulated well enough that they hardly need to run at all. If you don't have enough charging or battery capacity, get a propane or 12v/propane/110v hybrid kind. My TruckFridge uses up 5-10Ah a day, and most of those during the day when the sun is shining bright, so they're hardly any drain on the batteries.

I had made the mistake of buying a cheap thermo-electric cooler and ran it for a few months-- it used 4A, ran half the day, and didn't even cool the food properly (only 20 degrees F below ambient). Dumb dumb dumb-- I trashed my very expensive battery array that way. This was before I'd learned to actually measure anything before deciding whether (or how) to use it. The TruckFridge works a lot better and uses less amps.

Having a separate "house" battery from your starter battery is a good idea in all cases, and essential if you are charging anything more than a smartphone. The House battery (or batteries) should be an AGM or other deep-cycle-- designed to be run down deeply over a long period of time. Starter batteries are designed to provide cold-cranking amps (to start your engine) quickly and then expect to immediately start being charged back up by the alternator. They do NOT like being deep-cycled or run down slowly over time, the plates get sulfated (ruined).

Also, make sure you match the battery size to the amount of charging power you have. Solar panels only trickle-charge a large battery array-- it depends on how many amps it generates-- though a large solar array could bulk-charge a small battery no problem. I was dumb enough to buy 400Ah of battery capacity for a solar panel array that could only generate 15A when at full sun at noon in summertime. Some simple math would show why that was moronic: how long would it take for a 15 amps to charge up a battery array cycled down only part way, say to 300Ah, which would need 100Ah to fully recharge? It can't do it in one day for sure; there aren't enough hours of full sunlight, even in summer. Also, batteries need a few hours of continuous charging EVEN AFTER THEY ARE FULLY CHARGED to stay in good condition. You don't want to let deeply-discharged batteries-- even AGM's-- sit around for days or weeks (or months or years, as I did), before hooking them up to something studly enough to fully charge them within a few hours.

It's OK to have a larger number of amp-hour capacity in your batteries than you can charge up in just a few hours of sunlight at whatever amps your panels put out, but you'd also need an AC converter or genset (or both) that'll put out enough amps to really bulk-charge your batteries should you run them down, and be able to do that a day or two after running them down. (I bought a 75A 110V converter a few years ago and finally hooked it up at the beginning this year. Dumb of me to wait so long.).

My old G1 Android phone has 1.4Ah batteries, so charging it up from completely discharged state uses only a couple amps. I don't worry about it either. My panels generate 15A in sun in summer, and at least 5A even in fog and winter. The phone is a non-issue.

Back to the original question (from the vandweller's list) about leaving the charger plugged in: best to measure it and find out. I put an ammeter on my smartphone charger and found out that it uses 0.01A (10mA) when idling; so it's not crucial that I turn it off or unplug it all the time. Likewise the charger for my netbook uses 0.01A when the netbook isn't plugged in, and the netbook itself uses the same amount, so to have my netbook on and sleeping only uses 0.02A (20mA)! So that's something I don't worry about most of the time.

However, my dual-core 64-bit laptop and the charger for it uses almost 0.5A (500mA) when the computer is TOTALLY OFF (weird, or design flaw), and can draw up to 5A when running all-out! So I rarely if ever use it anymore, and only when in full sun and my house batteries are all charged up. I don't even have the big-screen monitor hooked up anymore.

Very long answer, but figured I'd share some of this at some point, and this seemed like a good enough place to do it.

Thursday, July 7, 2011

Productive day

I went to the car wash and pressure-washed (with soap!) my van. It looks better than it probably ever has. Fits in much more nicely in suburbia now. Maybe the neighbors will be happier with me. It was worth the $6. I may do this more often, And also I might avoid parking directly on the beach; the van gets soaked with spray and salt and gets very dirty-looking. I like it better clean.

Also, I put in two shelves at storage, one big one, and one mezzanine. I threw out 3 large garbage bags of crap I didn't need anymore. It's much more organized, so it'll be easier for me to get in there and clean up paperwork now, remove more stuff, and just be a more useful storage space.

I noticed my transmission grinding sound is back again, but only in 2nd gear. All the other gears are fine.

I also put together some trim items in the cab that I'd taken apart to get easier access for other work. It looks a lot cleaner now.

I've been really enjoying doing maintenance work lately! And home-improvement work, and even just cleaning and organizing. I like it. What's wrong with me? I was never like this, was always a creative type. Now I'm enjoying cleaning, maintaining, and organizing much more than creating.

I located my biodiesel hand-pump at storage, and it drove me crazy how dirty and rusty it is! I felt a compulsion to get a wire brush and some paint thinner out, and start cleaning it off. I had other work to do, so I put the pump in the van and I guess I can clean it off some other time.

I'm loving how my van runs now, how great it sounds. It's got a new low-end hum in its exhaust note, and feels like it has got a lot more power too.

I will very likely take a long trip on the California coast next month. I'm looking forward to it.