Fans, Cold, Aliner Mods

I’m continuing to work on the Aliner A-frame trailer. Unfortunately the current work that needs to be done is modifications to allow my modifications to work as intended. From the factory, the Aliner comes with little strips of plastic on the outside of the inner roof aluminum frame, which I assume are spacers so the upper roof doesn’t rub on the inner roof. These fell off of my Aliner quite a while ago and I tried to add new ones from materials I figured were comparable. Unfortunately they did not hold up and also fell off. But one of the additional problems that I have since I added the solar panels is that I’ve actually added some sharp raised surfaces that are scratching the lower roof aluminum siding. So not only do I need to have the plastic spacer so they don’t rub, but I actually have to add more thickness to them so there is space for the fasteners for the solar panels.

I think I have determined that a good way to solve this problem are these small plastic wedges that are used to level tables and chairs. I got mine up the street at the hardware store, but here is a link for the same thing at amazon. They are about an inch wide and an inch and a half long and

...
are tapered in thickness so they will spread out and add clearance between the two aluminum sides. I also decided that instead of using the rubber-based contact cement I used before, I will use real epoxy glue. Although following my usual modus operandi, I didn’t really do a full plan, I just kind of winged it. So of course I put the wedges and glued them on without really making sure they were in the right spot. So the ones closest to the solar panels are rubbing the fasteners that hold the solar panels on. I’m hoping that’s not really a big deal. Perhaps the fasteners will just wear a groove into the plastic of the wedges. Otherwise though, I think this was a good substitute for what was originally on there.

I also showed off my upgraded refrigerator cooling fans. The refrigerator in the Aliner’s, and I believe all A-frames, are cooled with fans because they do not have any kind of reliable draft or circulation for heat to dissipate away from the refrigerator’s fins and coils. The original fan in the Aliner is extremely noisy and uses almost 1/2 amp of electricity per hour. So on a warm day when you need to run the fan from 9am to 9pm, that can eat up 6 to 8amps of power. The new fans I installed use about a 10th of an amp and only create 15 dB of noise. I used a couple of self tapping screws to screw them to a piece of aluminum angle iron I had lying around, and then used the same self tapping metal screws to screw the angle iron to the wooden frame of the Aliner. They are 120 mm 12 volt computer fans  and they move 75 CFM of air, which I believe is more than the original fan. They make an amazing difference on the temperature of the counter-top just above the refrigerator.

The one tricky thing about installing the fans is  the wiring.  The cooling fan in my installation had a thermocouple in line in the wiring.  While there is a switch to turn the power on and off, the fan will not actually come on unless the fins of the refrigerator are above 90° F.  I actually just cut this thermocouple out of the wiring and wired directly to the switch.  You might want to leave the thermocouple in place, as it will save a little bit of electricity.  However that means you have to work on the refrigerator while it’s hot or you won’t know if your installation is working.  The other little snag is that the new fans had three wires. I assume that was because they are two speed, or maybe because they have a thermostat. In either case when I hooked mine up I just turned on the fan switch and made sure the wires were hot using a voltmeter. And then I continued to swap the fan wires with the hot switch wires and grounds until the fans worked in the direction I wanted them to(blowing OUT). It did take several different combinations of tries, but eventually I found the proper combination to power the fans. At night when I lie in bed and it’s really quiet, if I concentrate carefully I can just hear the fans if they’re running. I cannot hear them over the sounds of crickets or bullfrogs though, so they are quiet.