How did you cut 145mm hole in caravan floor for diesel heater

[Jared01]

Hello,

I purchased a diesel heater and will be installing in the coming days/weeks.

I am thinking of the craftright hole saw kit from bunnings ($20), use the largest diameter (127mm) then use a file to make the hole larger?

If I purchase that kit, I can use the other sizes to make a hole for the hot air duct/directional outlet.

https://www.bunnings.com.au/craftright-16-piece-holesaw-set_p6372275

Would be good if I had a "Reciprocating Saw" for my Bosch blue equipment, but that is quite expensive.

Wondering how others cut the ~145mm hole in the caravan floor?

 

[mikerezny]

Hi,
if there was sufficient clearance around the hole, I would use a jigsaw. Filing, by hand, to enlarge 127mm to 145mm is a lot of work!

Otherwise, I would drill a circle of much smaller holes with each one just touching the edge of the 145mm circle. Then use a file or small saw to cut out the pieces between the holes.

cheers
Mike

 

[Bellbirdweb]

I tried to use a hole saw I had which was designed for installing down lights in the ceiling but found there wasn’t enough space to fit it in, so I ended up using a jigsaw.

 

[Jared01]

Perhaps I could use a hand saw to finish the hole off?

Unfortunately the caravan is parked on the street and I am limited to battery equipment.

 

[Bellbirdweb]

Perhaps I could use a hand saw to finish the hole off?

A coping saw would be the way to go if your were going to use a hand saw.

The floor isn’t that thick ply so it’s fairly easy to cut.

 

[icetechaus]

Altroncs have a 140mm hole saw or you could use a milling bit for the drill.https://www.bunnings.com.au/haron-reamer-and-countersink_p6357562

 

[Crusty181]

$10 Gyprock saw will easily cut a circle through the ply flooring

 

[SkinnyBuddah]

Router with circle cutting jig

 

[Drover]

I'd use and did, a jigsaw if you don't have one just a cheap coping or plaster saw from Bunnings.

 

[Jared01]

Thanks for the feedback.

Going to install the heater today. Will try to take some photos and report back on my experience and install.

 

[Jared01]

Successfully cut the hole by using a hole saw and cutting a number of holes around the edge and then cutting the remainder pieces with the hole saw too then filing the rest.

Installed the heater finally. All wiring went through existing spaces (from under the bed, through the back of the drawers, under the sink, over the wheel arch/under the fridge and back to the battery). I had to cut the ring connectors on the end of the cable (for attaching to the battery) and clamps on larger ring connectors). I drilled about a 14mm hole for the controller connector to pop through and then mounted the controller as per picture.

Happy with the end result. Will post up some photos tonight.

 

[Jared01]

Some photos from the install.

Realised I didn't get a good photo of the muffler/exhaust or fuel tank/location.

Was trying to install it to the side under the bed but there were too many things underneath (gas lines, water pipes etc). Probably should have made it more towards the awning side but happy enough

I just bought my own 5L jerry and battery box (box was half price as there was a missing lid, so got it for $10, bargain).

I was expecting more hot air to come out faster from the exhaust, so I now am not so worried about where it is exhausting too (I thought the heat might heat up the bottom of the caravan floor or go up the side of the caravan etc) but it is quite mild. There is more noise coming from the combustion air silencer.

I ran the fuel line inside some split tubing and cable tied as shown in the photos.

All up happy with the product. Will give it a decent run on a 1 night trip on Saturday night.

I ended up buying the Belief Tuite 2.2KW heater from http://www.dieselheat.com.au

 

[Drover]

That's the shot, my exhaust just shoots to the ground and I'm thinking of making a 50mm intake pipe with screen on the end in the hope of making the suction a bit quieter outside....usually a bit of breeze to blow any fumes away.

 

[Jared01]

Going to give the heater a test run on Saturday night. Some photos of the exhaust now. Cleaned out the tunnel boot and under the double bed as well as bottom bunk and removed unnecessary items. Getting ready for central Australia trip in July

 

[Drover]

I'd just support that waggly end bit as it will just split after awhile from vibration....................

 

[BaldEd]

I didn't have enough room to be able to use a jigsaw so I drilled a ring of small holes, a few millimetres inside the circumference of the base plate shroud, then knocked the centre out. The rough hole edge I then smoothed to the exact hole circumference I needed with a small sandpaper drum fitted to my Dremel tool. The Dremel tool made a very quick and neat job of it. Sealed the plywood hole edge with paint to waterproof it and once the base plate was installed Silaflex'd around the shroud.

 

[Scrounger]

You know the toasters that you get at the camping shops the ones with stainles steel mesh to defuse the heat.
Well if you bye a spair piece of mesh and a circle clamp, cut a circle of stainless mesh and pop it over the exhaust and then clamp it.
Its a lot better than trying to clean out a wasp nest.
I imagin that you have done it but dont forget to get the sickaflex

 

[Pilchards]

Looks great Jared01, how did the heater perform and when you ordered the heater did it come with all outlet grills and ducting fittings etc.
Cheers Pilchards.

 

[Jared01]

Looks great Jared01, how did the heater perform and when you ordered the heater did it come with all outlet grills and ducting fittings etc.
Cheers Pilchards.

I was going to try the heater out this weekend but the weather was so bad in Sydney so I postponed until next weekend.

I paid for the ducting that attaches to the grills and for 2 grills themselves. Belive it was $55 or 60 for that option.

Checkout the website I quoted and or get in contact with the seller. They sent me a very detaile list of options and accessories most of which I bought such as muffler, pump silencer etc.

Will post back when I gave given the heater a 1 night trial before our 3 week central australia trip I July when we will use every night

 

[Jared01]

I put the heater to it's first test on Saturday night.

Was about 4-5c at night.

Kept it on it''s lowest setting through most of the night but then woke up during then night and turned it up 2 more fan speeds higher as the double bed in the Starcraft was a little cold but I think we may need to get a woollen underlay to solve that problem.

So I am very happy with the heater. The kids love it and like to stand in front of it in the morning when getting changed. The floor of the caravan is quite cold but I guess that is because of there only being a wooden floor and no insulation. Some thick socks when walking around in the caravan solved that problem for now.

I could't really hear the "ticking" of the heater.

Battery level got down to 12.4v after the nights use of stereo/lights but charged up again when the sun came out.

I ran the heater on constant heat output (instead of thermostat mode).



I would recommend this heater and seller for anyone considering buying one for their caravan. Installation is pretty straight forward too.

Will give it an ultimate test for 3 weeks using it every night in July.


Any questions, let me know