*NOW BOOKED FOR 2024* Transitmania 15 @ Santa Pod 19th to 21st July 2024 *ALL DETAILS HERE*


Custom calorifier + Webasto Thermotop

Post here camper and camper conversion related stuff!

Moderator: Luke

Custom calorifier + Webasto Thermotop

Postby Blizz » Thu Mar 16, 2023 12:49 pm

Hello,

I wanted to share my custom hot water system although I haven't invented anything new I think it could be interesting for someone.

I built a custom calorifier. Why custom if there many ones one the market? Basically because I could not fit the market ones where I wanted. My van is a L2H2 (130" MR) FWD wich means it has 10cm (4") more head space inside because floor is lower than RWD/AWD versions.

I started ordering a custom made SS tank with the fittings I needed. A big 1" thread for an electric resistor, two 1/2" more for the inlet/outlet and two small ones for drain/temp sensors.

Ordered with one of the ends unwelded.

Image

Image

Image

Then had a pipe bending company build a coil made of 16mm SS. Welded some tabs to rest against tank walls.

Image

Image

With the idea of taking profit of my solar surplus I installed a 12V 200W resistance. It's slow but quite cheap so I can put a bigger one if I want.

Image

Welded the cap and the coil pipes toghether

Image

Installed some fittings on the coil's ends

Image

Image

As my van is still under warranty I prefer to avoid teeing the engine coolant's system (But it's the v2 idea) so i bought a flashed OEM BMW Webasto Thermotop from salvage yard and tried the system outside, redneck style

Image

Image

After the test which was good, I bought some chimney pipe and end caps to develop the tank outer cover

Image

Cut it to size

Image

Put the water tank inside and let's do a cake. Used insulation PU foam

Image

After curing I cut the excess

Image

Cut some holes on the caps

Image

Finished product

Image

(Continues)
Blizz
Transit Aficionado
Transit Aficionado
 
Posts: 135
Joined: Sat Oct 23, 2021 12:21 pm
Location: Barcelona, Spain

Re: Custom calorifier + Webasto Thermotop

Postby Blizz » Thu Mar 16, 2023 12:54 pm

I used a long copper pipe for the tank cold water inlet to be far from the hot water outlet.

Image

Installed a thermostat mixing valve and pressure relief with check valve too

Image

Located the place for the water pipes to go in and out of the van

Image

All my van's water system is done with PERT-AL-PERT pipe and press fittings, made all that was possible to do out

Image

That's the space I designed the calorifier to go, did four holes and installed rivnuts

Image

Phew! All fits and nothing sticks out more than the diesel tank

Image

Before installing the valves and isolating the hoses

Image

If possible, I always like to prepare my wiring outside. This is the Thermotop power supply, starting signal and temp sensor wiring

Image

Installed a Y on the aux fuel port (I already had an Autoterm Planar 2D heater installed on it)

Image

Image

Image

Tried to route all the wiring and pipes the best I could

Image

Crossed to the passenger side over the heat shield parallel to an OEM wiring loom

Image

Image

Image

(Continues)
Blizz
Transit Aficionado
Transit Aficionado
 
Posts: 135
Joined: Sat Oct 23, 2021 12:21 pm
Location: Barcelona, Spain

Re: Custom calorifier + Webasto Thermotop

Postby Blizz » Thu Mar 16, 2023 12:58 pm

Designed a support plate and got it laser cut

Image

Bolted the plate to the Thermotop and the set to the van body

Image

Intake and exhaust where temporary, those are the OEM BMW ones cut to fit

Image

Designed a small protection plate to avoid road splash

Image

Image

After some paint and installed

Image

Made a temp support for the expansion tank

Image

The pipes coming/going to the calorifier are under the kitchen's sink

Image

Now I'm using the system completely independent to the engine cooland system. Thermotop takes 10 minutes to rise my 15l hot water tank to shower ready temperature. I plan to connect it to engine's cooling circuit in a future but I'll wait (Van it's still under warranty)

I'm super happy with the system. I installed an intake silencer and still need to installe an exhaust one altought the noise the Thermotop makes is more a "plane" or turbine sound rather than combustion noise.

Hope you like it!

Cheers,

David
Blizz
Transit Aficionado
Transit Aficionado
 
Posts: 135
Joined: Sat Oct 23, 2021 12:21 pm
Location: Barcelona, Spain

Re: Custom calorifier + Webasto Thermotop

Postby Altransit » Thu Mar 16, 2023 1:08 pm

Nice work 8)
1994 Mk4 SWB 115 Minibus 70ps Di (R.I.P.)
1997 Mk5 SWB 115 Minibus 70ps Di (Gone, but not forgotten!)
2004 Mk6 SWB T280 Medium Roof 85PS 2.0 TDDi - Vantunered (Also gone)
2008 Mk7 SWB T280 Medium Roof 85PS 2.2 TDCi - Also Vantunered
User avatar
Altransit
Site Moderator
 
Posts: 40197
Joined: Tue Oct 17, 2006 12:23 am
Location: Bicester, Oxfordshire, UK

Re: Custom calorifier + Webasto Thermotop

Postby johnporter11 » Thu Mar 16, 2023 10:40 pm

I see you've used extruded aluminium also....
johnporter11
Transit Aficionado
Transit Aficionado
 
Posts: 172
Joined: Mon Nov 16, 2020 11:07 pm

Re: Custom calorifier + Webasto Thermotop

Postby Blizz » Fri Mar 17, 2023 9:28 am

johnporter11 wrote:I see you've used extruded aluminium also....


Yes, and I love it.

Not cheap but the finish is so good and sturdy...

Cheers,

David
Blizz
Transit Aficionado
Transit Aficionado
 
Posts: 135
Joined: Sat Oct 23, 2021 12:21 pm
Location: Barcelona, Spain

Re: Custom calorifier + Webasto Thermotop

Postby johnporter11 » Fri Mar 17, 2023 8:27 pm

45.JPG
Snap!
You do not have the required permissions to view the files attached to this post.
johnporter11
Transit Aficionado
Transit Aficionado
 
Posts: 172
Joined: Mon Nov 16, 2020 11:07 pm


Return to Camper vans and conversions



Who is online

Users browsing this forum: No registered users

This site contains affiliate links for which we may be compensated.