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After 36 years of service, the refrigerator died.  Installing a new refrigerator is not just "plug and play" - - there is some work involved.
Most of these photos can be viewed at 200% to 400% actual size with reasonable resolution if you copy the to your own photo-viewer/editor.

First, there is a time of mourning for the old refrigerator.
Besides, the black plastic bags reduce the influx of the hot outside air.

Using the ice-chest reminds me of how much I really like having the convenience of a refrigerator (instead of getting new bags of ice every few days).

After some consideration, I decided to order a dual-voltage compressor operated refrigerator.  It uses 120-volt AC when available, then uses 12-volt (or 24-volt) DC as a backup source (with an automatic switch-over from AC to DC).

Since I do most of my traveling during the day-light hours, I will be able to leave the refrigerator running (with the solar panels supplying the necessary current), even during my frequent fuel stops. 
When using the propane mode of the old refrigerator the following dance was required:
  stop before entering the service station, turn off the refrigerator;
  drive on into the station and fill up;
  drive out of the station,  re-light the refrigerator pilot-light.

This new unit is supposed to operate when the trailer is parked on slopes up to 30 degrees off level (well beyond the slant at which I care to sit or sleep).

It arrives.

The carton has been removed, there are the doors.  They are without the decorative inserts, which I plan to make from Formica matching the old trailer's counter-top, table, and prior refrigerator inserts.

Stepping around to the side of the refrigerator, the compressor is evident, but the cooling coils are difficult to see.

 

It appears that I adjusted the camera angle to suit the refrigerator, rather than the trailer which is really level fore to aft.

Now, from the back the cooling coils are visible - - just like a household refrigerator in appearance.

The defrost drain is in its coiled shipping position.

The back of the 120-volt controller box is visible on the top of the unit.

Looking closer at the top, there are three control boxes: 
  at the back edge is the 120-volt unit,
  in front of it is the 12/24-volt inverter unit,
  and there is a smaller black temperature control box to the right (in this view).

Later: Checking the power leads to the compressor when it is running shows it is using a 16-volt 45-Hz alternating current supply (measured using an multi-function Fluke meter).

Looking a bit closer at the black control box and the 12/24-volt box, it has multiple fuses at 15 amps, however it rated to draw just less than 3.5 amps (on 12 volts).

 

Unfortunately, you can not remove the top front grill without pulling the refrigerator out of its space in the cabinets.  See the black-bolt-head, silver-washer and black bracket in the lower right of the picture.  There is another bolt-down on the far side of the 12/24-volt box at the end of that triangular plastic support.

Around to the front again, looking a little closer at the top grill and control dial.

This refrigerator is built expecting to cool itself using air drawn (mostly by convection) in underneath the front of the unit, up the back, and then out over the top of the box. 

Here are the current vents on the trailer for the refrigerator.

The bottom silver louvered refrigerator access door,
   the middle riveted-in golden ventilation panel,  and
   the roof-top refrigerator vent.

I will retain these, and modify the installation to use back venting.
This simple vent-stack ventilation worked well with the older refrigerator, even though it was producing much more heat in the process. 

With some help for the weight, and especially for the narrow doorway clearance (about 3/8 inch to spare) - - the refrigerator is parked inside.

Here it will sit until I can get the necessary remodeling done.

I have yet to replace an appliance in the trailer where there was not some adjustments for different sizes required.

So this is my early morning view for the next week or so.  There is just enough room to get around without injury, although access to the kitchen drawers was limited.

In this view, the refrigerator cabinet space (on the right) is no longer covered in black.  It is time to do some hands-on comparative measurements to determine how to fit the smaller refrigerator into the old space.

Notice the old support base extended out from the cabinet about two inches.  This was flush with the front of the old refrigerator base/doors.
In order to remove the old refrigerator, it was necessary to remove the bottom of the cabinet compartment above it.

This also made access to the fuse block (behind the reflective semi-clear plastic cover) easier.

Since it is hot outside (to the point I am using the air-conditioning), the vents have been stuffed with insulation for the duration of the project. 

Before the "big hail storm" (story elsewhere), the white fan ran from a miniature solar-panel on top of the refrigerator roof vent.  It has become time to discard it.

The two three inch (3") 12-volt computer fans normally are positioned in a panel on the refrigerator access door.  There is more than one use for chop-sticks.

The gray cord loops back up to the trailer's control panel.
The white/ivory refrigerator cord is "capped off" - it was not practical to reach the plug before removing the old refrigerator.

The soda can is for size reference.

A more top-to-bottom view of the back wall of the refrigerator cabinet.

Notice the left-hand side wall is merely the outside of the cabinet surface panel (by the entrance door).  This seems to be a common problem in RVs where the refrigerator compartment is vented to the outside and no insulation is provided to the adjoining spaces.

I had stuffed/shuffled/slid/coerced the pink fiberglass insulation into the space between the old refrigerator and this interior wall to moderate the heat gain/loss.  That was done without removing the refrigerator - - mostly through the lower outside refrigerator access door, a little by removing the floor of the cabinet above.

And viewing higher up to include the cabinet above the refrigerator.

The "sagging" insulation, is stuffed up into the vertical vent behind the back wall of the upper cabinet.

Looking up from the base of the refrigerator compartment, into the cabinet above and beginning to see into the vertical vent space that leads to the roof vent.

Keep your eyes on the bundle of wires, we will explore it further.

Now a better looking-up view that shows the fuse block (behind the semi-clear plastic cover), and the back of the trailers control-panel box.
Without the pink stuffing, and getting serious about attacking the work at hand, some pictures of the 'before'.
... before ...
... more before ...
... definitely getting more serious now, the debris has been removed ...

 

While you were looking elsewhere, I decided to use the finished top of the opening as the "build-to" point.  This means the old base needs to be raised several inches.

So, take one last good look at the old refrigerator's platform...

... which was supported by this box of one-by-six (1" x 6") boards ...
... and now the real trailer floor appears ...

The copper tube in the right rear corner (coming up through the sheet metal plate) is the old propane supply.  That has been capped off below the trailer, this stub of pipe remains for a later project.
    I have obtained parts for re-plumbing the propane into the expanded empty space, including a quick-disconnect fitting.  That would allow using one of those free-standing not-directly-vented propane heaters when needed.

So, having established the foundation level, it is time to address the 12-volt power supply.  There was previously no need for 12-volt in the old refrigerator,  it worked well without computer-boards - thank you.

So here we have four fuses (and a spare);  some examination will lead to deciding where to share power.

But first, let's take a look again at that bundle of wires.

The blue wires are the positive side of the 12-volt trailer system.
They are connected here to a "shunt" that is used to measure the overall current usage in the trailer (original equipment).  The green wires are the sensor leads to the control panel meter. 

The fat brown wires are ribbon-cables that go to the holding tanks - tank fluid-level sensor leads.

The smaller  white and brown  plus  red and green  bundles are special to this vintage trailer.  They actually run all over the trailer.   The "in folks" of the late-60s and early-70s probably already know the purpose of these wires.

Taking another look at the 12-volt system ...
... to which a white negative lead has been added ...

... and a red (because the refrigerator uses that color code) positive lead has been tapped into the system ...

... the red lead has been looped up in anticipation of adding a switch.
Two  two-by-twelve (2" x 12") boards on edge have been ripped to the proper height and braced into place.

The one-by-sixes are from the old support box.

The two-by-twelve boards have been placed directly under where the skid base of the refrigerator will rest.  They have been notched at the rear because the support only needs to go so far back - that will give better access from the outside access door.

... a alternative perspective view ...
... a new 3/4 inch plywood base finishes the new cabinet bottom.
A switch has been added so that I can have absolute control over the 12-volt power supply to the refrigerator.

The floor of the upper cabinet has been replaced.

Some 1/8 inch grid wire hardware cloth (heavy screen) was spray painted flat black and fitted to the two side vents.
   Years past I had added such screen to the top vent.  This helps keep out mud-daubers, wasps, bats, other small critters, and leaves.
The sides now have insulation to fill in where I had previously stuffed the pink fiberglass (on the left), plus another half-inch on both sides to accommodate the smaller width of the new refrigerator.

The front edge of the plywood was painted flat-black to match the new refrigerator bottom grill (thus disappearing "into the dark").
  If I were not going to use back-venting, I would have also used flat-black paint on the top few inches of the cabinet interior side walls and the forward section of the 'ceiling' of the compartment.  I would have painted further back on the base too.

A flat-plug three-prong extension cord replaces the old power connections.  The cord starts out hugging the wall instead of protruding into the open space.  This adapts to the reduced clearances behind the refrigerator.

The supply to the trailer's control panel now drops down to the end of the extension cord.

For some reason, Norcold has not understood the potential retro-fit issues:  they  use a straight-into-the-wall plug that requires more free space.

A new view towards the top, with the revisions in place.
Here the refrigerator is positioned for insertion into the remodeled cabinet.
A last look at the factory affixed model and serial number sticker.

That  "R"  on the end of the model number is going to be a problem.

A view of first fit into the cabinet.
And here is the "extra" space below the refrigerator resulting from elevating the support platform.
For now, just a simple cover plate over the space below the refrigerator using a portion of the old refrigerator door decorative Formica panels.

The top of the panel goes under the bottom edge of the refrigerator base grill.  Two magnetic latches hold it in place;  the door handles also serve as the bolts that secure the second half of the magnetic latches.

 

And, as can be seen, no empty space in an RV remains void for long.  Parts for the remainder of this project (plus a couple items from intervening projects) have already found a home.


  
The new home for the switch that controls the auxiliary ventilation fans (the pair of computer fans) is on the lower grill cover.
Meanwhile, on the backside (as seen from the outside refrigerator access door), the step-down portion of the support is being covered.

Underneath the vertical backing are a pair of angle-brackets that reach into the square-tube refrigerator skids.  This is to provide 'extra' control,  the old refrigerator had lag-bolts holding down the back side.

This vertical cover piece also needed to have notches for both the angle-brackets and the defrost drain tube.

You have probably noticed there are no screws installed yet.
This is part of the  "R"  issue mentioned above.  Norcold had not responded to a couple serious questions at the time of these pictures (this 'hung' the install process for four weeks - still waiting for a reply).

The two computer fans have been reinstalled, this time attempting to hold them in holes in the base.  They are not touching the back of the refrigerator.  We will see how well this handles the bumps in the road.

There is now a split in the controlled 12-volt line to the fans.  This will be used for a smaller fan to focus air flow over a particularly-hot hot-spot in the Norcold electronics. 

Without the fans, the space on top of the refrigerator, where the electronics reside, is about four to five degrees Fahrenheit above the ambient temperature.

With the two fans operating, the temperature is one to two degrees higher.

 

In theory, the fans might be more effective if they were mounted in the roof top vent itself.  Maybe some day I will explore this, however it will be difficult to measure their negative impact on convective-only flow (when they are not running).

Another view after tucking away the 120-volt cords (and moving the supporting stick to the left-hand side of the access door).

The foam and pink insulation batting are intentionally blocking the air flow underneath the refrigerator.  This is part of the adaptation of the unit to use the pre-existing backside exterior venting. 

Behind the front grills, top and bottom, are similar foam blocks - painted flat black to "hide" them in the dark behind the grills.

No, the clip-board is not part of the installation.  It is there to reduce the backlighting (entering the upper side-wall vent) for the photos.

In the foreground is the red and white 12-volt DC power lead to the refrigerator.

In the back is the smaller fan to boost air circulation over the two boxes of electronics on top of the refrigerator.

A closer view of the micro fan for ventilating the top-surface-of-refrigerator space.

 

To insert the Formica decorative door panel, I first removed the edging of the door and then was able to slide in the Formica.

In hind-sight, I realize it is possible to get enough bend/flex out of the laminate so that I only need displace the door edging.  OK!  The second door will be easier.

Here you see the alternative location for the door latch mechanism if the door was hung to swing on the opposite side.

 

The panel is now in on the lower door, the door edging propped up against the cabinet.
For both doors, a section of the foil covered bubble wrap style insulation was first pre-positioned on the door with a small a bit of tape.  This is intentionally sized slightly smaller than the available space to avoid structural stresses.
Back outside to cut to size the second door panel.

I used a laminate style bit in the Dremel tool,  and a cone-like adapter to stabilize plus guide the tool down the length of metal flat-bar stock that served as a straight edge. 

Both panels are now in place, the foil-faced bubble-wrap also reduces the shifting that is possible since the panels are not an absolutely tight fit in the door trim.
Finally, the edge trim has been added after inserting screws into the front of the cabinet.

 

Top section view.

 

Bottom section view.

 

*  *  * *  *  *
Now, for some soda-can based size comparisons:

I definitely have lost refrigerator space.

I did gain significant freezer space, both because of the physical box is larger, and because I no longer expect to be keeping a gallon-plus flat-bottom mixing bowl of ice in the freezer (which I used to keep the refrigerator section cool while traveling down the road).

Four refrigerator door shelves, 6 cans wide; comparable bottom deeper shelf to new refrigerator.  Freezer door shelf in new, none in old.

Five refrigerator shelves;  four are 6 by 4 cans, one is 6 by 3 cans.  One full shelf is not tall enough for upright soda cans, the others are.
So, 48 soda cans on the bottom two shelves
- leaving two and a half shelves for other stuff.

One of the shelves had a "flip-up" panel that allowed two half-gallon jugs to fit up against the wall when needed,  otherwise there was no loss of the available space.

The two "salad" drawers with their own covers had flavor (and spoilage) isolation advantages. Their net space was just slightly less than the new single tray.

First you notice the yellow/orange glow in the refrigerator - - I feel like I need to hurry up and finishing editing this so I can close the door (to turn out the light) !!

The freezer space is essentially twice as large, although the vertical space division could be perhaps more even.
The three cans are all that can fit from front to back, the door-shelf intrudes that far into the bottom of the freezer.

The small plastic tray in the second wire shelf is the 'fit one jug here' space.  Unfortunately this wastes the space behind it and to the left of it;  further the area on the shelf below it will not fit a vertical soda can.

So, 48 soda cans on the top-shelf plus half-middle shelf plus half-bottom shelf
- leaving one and a funny fraction shelves for other stuff.

The single "salad" drawer does not have the same level of closure as the older drawers.  It is slight larger in total capacity.

Here are both the door and main spaces.

I adjusted the shape slightly of the metal canned-drink cooling tray from the old refrigerator to fit into the door shelf of this one.

Three refrigerator door shelves, 6 cans wide; comparable bottom deeper shelf to old refrigerator.  Freezer door shelf in new, none in old.

The old refrigerator wire shelves would pull out for access to stuff in the back, the new refrigerator shelves are secured to the back wall with a cable-clamp and screw.

This new refrigerator seems more sensitive internal air flow issues.  Perhaps that is because the bottom of the freezer compartment is the primary cooling plate for the refrigerator section.
The old refrigerator had an independent cooling section in the refrigerator with fins (that was why there was a fractional top shelf).


This page last edited: 06 November 2007