Stainless waterproof box for RV water pump (build and installation)

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This thread will have a something like 50% welding and 50% general wrenching but I think it qualifies anyway. So here we go.At the beginning of the last summer season I fitted a custom made wáter tank under the trunk of my van. I got the polipropilene (10mm thick) tank made to my specifications and I installed it myself.The problem is that I used a fairly simple inline wáter pump paired with a non-return valve… which didn’t work as expected. The pump kept on un-priming all the time so anytime I wanted to get a shower, I needed to suck on the hose like a madman. It was driving me nuts.So recently I decided to fit a self priming pump. I chose a SHURFLO pressure wáter pump. It is meant for permanently presurized systems but I just wanted this pump due to its self-priming characteristics. I got my RV accesories supplier on the phone and the conversation went more or less like this:ME: I want a 10l/m SHURFLO pump.SUPPLIER: OK, it is already on your way. Where do you plan to install it?ME: Outside, just by the tank. I don’t have room inside my van and if I happen to have a leak, it is going to flood my forniture.SUPPLIER: Your call buddy but these pumps are not rated for outdoor use! Visible electrical contacts, non waterproof pressure sensor, etc.ME: Roger. But I promise you this pum is going outside no matter what.So here I am. I certainly hope this saves my pump from destruction!First I am goint to put together a stainless box made of 1,6mm stainless. I do have some 4mm as well, but I think it is waaay too much overkill. The challenge is that my only means to weld stainless is stick welding!Some measurements, some guesstimations and I start the cutting with my angle grinder and thin wheels. In order to make it easier to put together, I bent the two longer edges. I cut arround 75% and then bend. The least pieces I need to square before welding, the better.Seems like the wáter pump fits. However at the end I will install it croocked in order to  make room for the cable glands I used for the hoses.Sides cut and tacked the box together. 316 1,6mm rods at 30 Amps.I welded the box one small section at a time jumping arround to minimize distortion.Continues on the next post.....
Reply:This seems to be the so called suggaring. Now I understand all the rage about back purging! For this application it doesn’t make any difference (for me at least).I fixed the “flange” made off 4mm stainless stick welded with 2,5mm rods.I drilled the flange on the drill press… undersized (4mm) in order to redrill to 5mm after welding (just in case the holes get ovaled or something). And then tap to M6.I don’t have any pictures welding the flange to the box but I used 1,6mm rods at 45Amps. I could use some more heat because the flange is thicker and it sucks up the heat. Inside corner. Not having a mill to flat ground everything, I used a flap wheel.And now the proof that so many hours lurking in Welding Web makes you a better welder (to some extent). It doesn’t leak!Now it is time to redrill to 5mm and tap. I used some tapping fluid… stainless is tough!Now that the box is ready, it is time to fix the cover where the pump and fittings will be attached. Scribe the outline of the flange, cut, centerpunch the holes and drill oversize (to compensate for any missalingments.In this picture I am drilling the holes for the 25mm cable glands with the step drill in the drill press.After welding the 6mm studs that will support the wáter pump. Drill, tap, thread the stud and tack weld on the back side. Straighten with a rubber mallet and… done.Final result.Home made rubber gasket.Continues on the next post....
Reply:I made holes in the rubber using this tool. Mostly used for leather working… I have no idea how you call this in English! I used the biggest setting but a bit bigger would have been a better choice.Time to attach the box to the van. Three 10mm stainles bolts with nylock nuts.Pump installed on the cover with the neccesary hoses, fittings and electrical connections.And finally the whole thing installed under the van.Hoses are a tad exposed but nothing critical. I don’t do any heavy offroading with this van (even though it is a Syncro van). If it ever gets damaged, I will rethink it. Something along the lines of moving the hoses to the side of the box or something. More clearance (although now it sits above the protection of the wáter tank anyway) and less chances of ripping it off.Anyway I am totally happy with this setup. The shower now Works great! And I don’t have to prime it or worry about running it dry. I can almost use it as a preassure washer!I hope you enjoyed the reading as much as I enjoyed the building! It took me two half days to put it together and a couple hours installing it. I am in a rush! I am heading to the Alps for two weeks of alpine climbing on Monday and I wanted this to be ready.MikelLast edited by Mikel_24; 06-18-2014 at 05:20 PM.
Reply:Is that a vw vanagon syncro? The picture sure looks like the rear end (motor side) of a vanagon. I'm assuming its an external shower. Post some pictures of your van...Lincoln Idealarc Tig 300/300, Lincoln ranger 8, Lincoln LN-25, Miller Sidekick (keeps rockin!), Oxy/Acy torch, Miller XMT-304 with a Miller 60 series wire feeder and high freq. box, Profax positioner 8" chuck, Aaronson 3500# positioner 15" chuck
Reply:Nice work, Mikel!GravelThe difference between theory and practice is that in theory there is no difference.
Reply:Good job.  Let us know how it works
Reply:Excellent project!  Well thought out and well executed.Jerry30+ yrs Army Infantry & Field Artillery, 25 yrs agoMiller 350LX Tig Runner TA 210, spool gunLincoln 250/250 IdealArcESAB PCM 500i PlasmaKazoo 30"  vert BSKazoo 9x16 horiz BSClausing 12x24 lathe20T Air Press
Reply:Originally Posted by freshintulsaIs that a vw vanagon syncro? The picture sure looks like the rear end (motor side) of a vanagon. I'm assuming its an external shower. Post some pictures of your van...
Reply:I'm wondering if you ever cross borders with it, will they get excited about wanting to look inside that box.How about a little "inspection hole" and plug so they don't try and tear it all off ?
Reply:Nice van! And good job on the box (and kid). Here in the us we call your T4 a Eurovan. And many would love to have been able to buy a 4wd eurovan (T4) with a TDI!!! awesomeLincoln Idealarc Tig 300/300, Lincoln ranger 8, Lincoln LN-25, Miller Sidekick (keeps rockin!), Oxy/Acy torch, Miller XMT-304 with a Miller 60 series wire feeder and high freq. box, Profax positioner 8" chuck, Aaronson 3500# positioner 15" chuck
Reply:Well, back from the Alps I must say the shower system works great! Now if only I had hot water as well... LOL. This will be my next proyect probably.Regarding the inspection hatch... True, It may come handy when going to Morocco for example. I will take it into consideration and see how can I fix it.Freshintusla... I now remember this is called Eurovan in the states. I don't recall seen many of them when lurking on Pirate4x4, ExpeditionPortal and sites alike... Seems like the T3 Vanagon is much more popular. I also miss your Sportmobiles! I wish I could trade my van for a Sportsmobile from the states (plus some cash, of course!). We are in need of a somewhat more heavy duty / offroad capable vans (without jumping to the small truck category). There is no way you can find a vehicle with two solid axles, transfer case and enough inside room to make it a camper. The regular 4x4 (Defender, Toyotas, etc.) are too small. And the 4x4 vans are to mild for my taste (no low range, no front/rear lockers, limited suspension travel, small engines, etc.) And trucks are a whole other world. They don't fit where a van does, weight much more, require special maintenance, etc.As I said, I want a Sportsmobile bad!Mikel
Reply:Great job bro!!!!!! I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Great job on the build. Nice van. Hope you have a safe trip.
Reply:Originally Posted by forhireHope you have a safe trip.
Reply:Originally Posted by Mikel_24"Safe" could be a misleading word...
Reply:AWESOME pictures !!!