Day Two – Painting, Metalwork, and Electronics

Day Two – Painting, Metalwork, and Electronics

The first task of the day was to paint the chassis black. I’ve chosen matte black for the wooden parts, nothing special just a discount center spray can. I’ve got High Temperature paint for the metal parts.

While the paint is drying, time to get to work on the radiator. Instead of using beer or soda cans I am using galvanized 3” ductwork. I’ve got 25$ worth at a local home renovation center. I’ve cut 14 pieces thirty inches long. This gives me a few extra inches at the top and the bottom of the box to louver the airflow.

Now the chassis is dry and a rough fit-in is done. What you are seeing here are the 14 parts of the radiator, the painted chassis, and the glass panels. Looks like a good fit! I’ve used tape on the glass panels for illustration.

In theory, this type of convection furnace does not need any electronics, it works by the heating and cooling of air alone. This picture shows you the exhaust air vent, which will direct warm air inside the house. It’s been fitted with two pilot lights and an SPST switch, so it will also be the ‘control console’ for this. I am using six-pair cat5 cable to connect everything.

I am using a digital non-programmable cooling system thermostat inside the unit. It connects through the hot side of the circuit that powers the motors. This thermostat will only turn on the fans and the pilot light when the temperature inside the unit exceeds 25 degrees Celsius, blowing that warm air inside the house. Once the internal temperature drops again below 25C, the fans will stop. I’ve set it that no cycle can last more than 6 minutes, to give time for the air to warm up inside the unit.

Two pilot lights mounted on the vent inside the house will give a quick status. Since only half the wiring is finished, the light you see on here is connected to the fan circuit. It lights up when the fans are running. The switch will be a power mains, and will also have its own pilot, currently not connected.

The internal thermostat is seen here, tested and installed in its final spot inside the unit. You can also see the wiring, the fans, and the galvanized ductwork. Tomorrow I will mount the ductwork and paint it, insulate the unit, and complete the exhaust.


Continue to day three... more
Day Three – More Painting, Herringbone, Braces