- Prepare the box:
- Drill 4 holes in the top for 10-24 rod
- Cut big hole in the bottom. If using saber saw, support the sheet
well, or the welds on the box will shake loose. Alternative: use
dremel tool.
- Fit the extender box. Drill about 18 holes for self-tapping screws, mount
the extender box, and remove it again for now
- Cover up unused holes, move drain hole.
- Put in 5 sides of foam. Cut 0.25" relief pattern for copper tubes,
using the paper template. Cut holes and small funnel shape for
drain pan.
- Put in the lexan air hose output adapters
- Assemble and mount drip pan:
- The finished pan is 3.75×10×1" copper sheet; cut extra
0.25" tabs for lap joint at the corners
- Braze the four joints - test for leaks
- Hammer a profile in the bottom using the carved 2x10 block
- Drill a hole in the center, and use a countersink bit to hammer
a funnel shape; drill out to just under 3/8"
- Use countersink to shape the end of a 3-4" piece of 3/8 copper
tubing, hammer into hole
- Braze drain tube in place
- Make a bridge for the level sensor. Strip of copper, 1/4" pipe
thread tap. Folds to go over drip pan edge.
- Braze into place, screw sensor into tapped hole.
- Put drip pan assembly into the box, thread signal cable out.
- Assemble and mount coils:
- trim coil ends and assemble coils and straight pieces with
swagelock (1.25 turns) so that coils fit closely alongside each
other.
- space loops in the bottom coil such that there is space in the
center for the level sensor
- slide coils into the box
- slip on the mounting adapters, screw into place
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