3rd 180 mod - furnace heat deflector

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 After much noodling I think I came up with an answer to the furnace blowing hot air under the bed and then sucking it back in again while never heating the Pod evenly.Video link;  http://drive.google.com/file/d/0B_wD1bI-4-mdUVNYUXlKcDJMUDA/view?usp=sharing

There is now a template on page 2

I built a 22 gauge sheet metal can with heat reflective shielding that seems to work really well. It lifts off and goes on in seconds. Total cost: $16. 
 I've retained all the return air slots as they keep the unit cool by giving constant airflow down the sides of the furnace. And gave good flow to the small square vent in the bottom corner; which i can only call a very important cooling tunnel. When the furnace is running a good amount of air is pulled in here. I think the furnace actually runs better now only sucking in cool air and it heats the pod way more evenly. The original grill has 48.5 sq in. of opening, and this one has an opening of 5" X 10 1/2" for 52.5 sq in. I have seen a few attempts at this in the forum and took a hard look at the unit and think I got it. Let me know if you think I missed anything.

 I actually ran the cardboard prototype for 10 minutes to see how it worked and it never caught fire!

Here are photos of the process:The template. This was a puzzle! (the 5 1/2" sides are acually 6")
 Cutting, I used tin snips and a cutting wheel.
I don't have a pic of the 2 large bends, but I used a 1x6 screwed to the work bench with the metal sandwiched between it, and just bent it up. Smaller bends were done with a block of wood.

For small bends and seaming I used these:
 I used a pop rivet tool for all attachments.
I added curved pieces for less turbulence.
I then finished all the cuts that go around the furnace grill and covered it with heat sheild heat reflective tape.  I just realized the bottom return air isn't needed as the furnace sits and mounts to the plywood cabinet.
Did take 3 hours of playtime,(half of that was drawing the templet), I think a shop could do it 1. I'll ask my local guys what they would charge and let you know. 
Cheers! John

All my 180 mods

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voisj Members Profile Send Private Message Find Members Posts Visit Members Homepage Add to Buddy List Senior Member Joined: 19 Jul 2016 Location: San Luis Obispo Online Status: Offline Posts: 471	Topic: 3rd 180 mod - furnace heat deflector Posted: 24 Nov 2016 at 2:45am
	After much noodling I think I came up with an answer to the furnace blowing hot air under the bed and then sucking it back in again while never heating the Pod evenly. Video link; http://drive.google.com/file/d/0B_wD1bI-4-mdUVNYUXlKcDJMUDA/view?usp=sharing There is now a template on page 2 I built a 22 gauge sheet metal can with heat reflective shielding that seems to work really well. It lifts off and goes on in seconds. Total cost: $16. I've retained all the return air slots as they keep the unit cool by giving constant airflow down the sides of the furnace. And gave good flow to the small square vent in the bottom corner; which i can only call a very important cooling tunnel. When the furnace is running a good amount of air is pulled in here. I think the furnace actually runs better now only sucking in cool air and it heats the pod way more evenly. The original grill has 48.5 sq in. of opening, and this one has an opening of 5" X 10 1/2" for 52.5 sq in. I have seen a few attempts at this in the forum and took a hard look at the unit and think I got it. Let me know if you think I missed anything. I actually ran the cardboard prototype for 10 minutes to see how it worked and it never caught fire! Here are photos of the process: The template. This was a puzzle! (the 5 1/2" sides are acually 6") Cutting, I used tin snips and a cutting wheel. I don't have a pic of the 2 large bends, but I used a 1x6 screwed to the work bench with the metal sandwiched between it, and just bent it up. Smaller bends were done with a block of wood. For small bends and seaming I used these: I used a pop rivet tool for all attachments. I added curved pieces for less turbulence. I then finished all the cuts that go around the furnace grill and covered it with heat sheild heat reflective tape. I just realized the bottom return air isn't needed as the furnace sits and mounts to the plywood cabinet. Did take 3 hours of playtime,(half of that was drawing the templet), I think a shop could do it 1. I'll ask my local guys what they would charge and let you know. Cheers! John All my 180 mods
	SLOPODMODS John&Sue,SLO,CA 2016 180 HRE, 2013 F150 Eco Boost

Grandpa Hiker Members Profile Send Private Message Find Members Posts Add to Buddy List Senior Member Joined: 04 Jan 2015 Location: Martinsville, V Online Status: Offline Posts: 143	Posted: 24 Nov 2016 at 4:50am
	Such a great idea. If you were selling them, I would be buying one!
	Rob & Becky 2014 Ford Explorer 3.5 SOHC V6 2015 R-179 Pod aka Piddle Pod "Life is not about waiting for the storms to pass, it is about learning to dance in the rain!!"

jato Members Profile Send Private Message Find Members Posts Add to Buddy List Senior Member Joined: 23 Feb 2012 Location: Kewadin, MI Online Status: Offline Posts: 3216	Posted: 24 Nov 2016 at 6:53am
	Make that 2 ! If you aren't going into production, guess I will have to copy your idea and make one. Looks great. Thanks for sharing.
	God's pod '11 model 177 '17 Ford F-150 4WD 3.5 Ecoboost Jim and Diane by beautiful Torch Lake "...and you will know the Truth and the Truth will set you free."

StephenH Members Profile Send Private Message Find Members Posts Add to Buddy List podders Helping podders - pHp Joined: 29 Nov 2015 Location: Wake Forest, NC Online Status: Offline Posts: 6285	Posted: 24 Nov 2016 at 9:33am
	I think you covered the essentials of having the return air free. That was the problem with some others I saw. This looks good, and I will be thinking of using your example also. Thank you for posting it. Do you have a sheet metal brake that you used to make the bends in the sheet metal? If not, what did you use? I think the only thing I would make sure of is that the area of the air output of your duct is equal to the area of the output on the grill so that there is no restriction in air flow.
	StephenH Happy is the man that findeth wisdom,... ouR escaPOD mods Former RPod 179 Current Cherokee Grey Wolf 24 JS

voisj Members Profile Send Private Message Find Members Posts Visit Members Homepage Add to Buddy List Senior Member Joined: 19 Jul 2016 Location: San Luis Obispo Online Status: Offline Posts: 471	Posted: 24 Nov 2016 at 12:47pm
	Stephan, I saw your thoughts in another link on the deflectors some built and thought , "challenge excepted"! The furnace grill openings are 48 sq inches and the front facing opening on this one is 52.5 sq inches (5"X10.5"). No break, I used a square edge 1 x 6 screwed to my work bench flush with the front edge. with the metal under it for the large 2 bends and these for the small bends, I'll add a few more pictures to the op.
	SLOPODMODS John&Sue,SLO,CA 2016 180 HRE, 2013 F150 Eco Boost

StephenH Members Profile Send Private Message Find Members Posts Add to Buddy List podders Helping podders - pHp Joined: 29 Nov 2015 Location: Wake Forest, NC Online Status: Offline Posts: 6285	Posted: 24 Nov 2016 at 2:53pm
	Thank you for the additional information. You obviously did think this through. Great work!
	StephenH Happy is the man that findeth wisdom,... ouR escaPOD mods Former RPod 179 Current Cherokee Grey Wolf 24 JS

StephenH Members Profile Send Private Message Find Members Posts Add to Buddy List podders Helping podders - pHp Joined: 29 Nov 2015 Location: Wake Forest, NC Online Status: Offline Posts: 6285	Posted: 15 Mar 2017 at 10:52am
	Were you ever able to get up with a shop and get a price to have these made?
	StephenH Happy is the man that findeth wisdom,... ouR escaPOD mods Former RPod 179 Current Cherokee Grey Wolf 24 JS

voisj Members Profile Send Private Message Find Members Posts Visit Members Homepage Add to Buddy List Senior Member Joined: 19 Jul 2016 Location: San Luis Obispo Online Status: Offline Posts: 471	Posted: 15 Mar 2017 at 4:27pm
	Sorry, I'll go by today after work. But since the twin bed thing looks like it may work,I may not need it and happen to be coming your way!
	SLOPODMODS John&Sue,SLO,CA 2016 180 HRE, 2013 F150 Eco Boost

StephenH Members Profile Send Private Message Find Members Posts Add to Buddy List podders Helping podders - pHp Joined: 29 Nov 2015 Location: Wake Forest, NC Online Status: Offline Posts: 6285	Posted: 15 Mar 2017 at 5:13pm
	Okay. Thanks.
	StephenH Happy is the man that findeth wisdom,... ouR escaPOD mods Former RPod 179 Current Cherokee Grey Wolf 24 JS

voisj Members Profile Send Private Message Find Members Posts Visit Members Homepage Add to Buddy List Senior Member Joined: 19 Jul 2016 Location: San Luis Obispo Online Status: Offline Posts: 471	Posted: 16 Mar 2017 at 1:15pm
	Stephan, My sheet metal guy says 1/2 hour labor ($47) and $8 materials for a total of $55 plus tax, So $60 ish. This does not include the frost king wrap I got at Home Depot($11) If I did 10 of them it would drop the price of each one by 20%. He thinks it's a perfectly good design and wouldn't change a thing,(Yay, me!). rgds John
	SLOPODMODS John&Sue,SLO,CA 2016 180 HRE, 2013 F150 Eco Boost