A quick update on the progress of the sheet metal.
Months ago, when I ordered the cold-rolled steel for the frame, I neglected to actually measure it when it was delivered. I therefore missed the fact that the supposed 1/8" x 2" was in fact 1/8" by 2 1/4". As a result, the base of the frame was a 1/4" too high meaning that the hole in the backsplash for the group didn't line up with the flange on the boiler. I cutout and remade the cross bars, cleaned up the (now rather beaten-up) frame uprights and put everything back in its place.
While doing so, I welded on a couple of tabs to keep the backsplash in place. The tabs, together with the last interior flanges of the cover create a track for the backsplash to slide into.
The tab clamped in place before welding.
The cross bars must be set back by at least same distance as the tabs. A scrap of 3/8" bar plus a brass shim create the necessary thickness.
Back to where we started!
Now for the fun part! I made a change to the design because I was unhappy with the placement of the pressure gauge. There is just enough room to fit the gauge and a u-bracket between the upright and the exterior of the cover.
This gauge is both easier to read in this position and is now flush to the exterior surface. Far more satisfying all around.
I knew there was a reason to put a coil in the line to the manometer! It was an easy job to reshape the existing part and to re-orient the coil so that the condensate runs back into the boiler.
AND... just because I like to feel like I've achieved something today, a test fit of the case parts with (yet another) valve.
Hmm. This thing is starting to look vaguely like a coffee machine.
Months ago, when I ordered the cold-rolled steel for the frame, I neglected to actually measure it when it was delivered. I therefore missed the fact that the supposed 1/8" x 2" was in fact 1/8" by 2 1/4". As a result, the base of the frame was a 1/4" too high meaning that the hole in the backsplash for the group didn't line up with the flange on the boiler. I cutout and remade the cross bars, cleaned up the (now rather beaten-up) frame uprights and put everything back in its place.
While doing so, I welded on a couple of tabs to keep the backsplash in place. The tabs, together with the last interior flanges of the cover create a track for the backsplash to slide into.
The tab clamped in place before welding.
The cross bars must be set back by at least same distance as the tabs. A scrap of 3/8" bar plus a brass shim create the necessary thickness.
Back to where we started!
Now for the fun part! I made a change to the design because I was unhappy with the placement of the pressure gauge. There is just enough room to fit the gauge and a u-bracket between the upright and the exterior of the cover.
This gauge is both easier to read in this position and is now flush to the exterior surface. Far more satisfying all around.
I knew there was a reason to put a coil in the line to the manometer! It was an easy job to reshape the existing part and to re-orient the coil so that the condensate runs back into the boiler.
AND... just because I like to feel like I've achieved something today, a test fit of the case parts with (yet another) valve.
Hmm. This thing is starting to look vaguely like a coffee machine.
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