Help brainstorm ideas to build a *safe* vented propane bottle box

[One Awesome Inch]

I am trying to come up with a good design for a vented propane bottle box. I'll be using 1/2 inch plywood and drilling a hole out the bottom of the van for any propane to vent outside the van.

My main query is how to build something air tight so gas can't get into the van, yet still have it super easy to open and access the knob to turn the gas off and on. I'll likely be doing that multiple times a day since I dont want to drive with the gas on.

One idea I had was to use square aluminum tubing to build the frame of the door to make sure the wood does not warp, as wood tends to do. However, with the hinges I am not sure closing the door would keep things air tight, even with the use of gasket tape / weather stripping.

I also thought of using the top as a lid combined with thumb screws but then if I do that, I lose the space above the propane bottle box (that could be used for storage).

Thoughts, ideas, suggestions?

 

[gypsychic]

Hi One Awesome Inch,

I saw many boxes set-up this way when I looked at European DIY campervans, especially in England. Many discussed how they built the propane box. I'd look there for some ideas.

GypsyChic

 

[Optimistic Paranoid]

Take a look at http://www.westmarine.com/buy/t-h-marine--designer-series-hatch-11-x-15--15752223

Something like that would make it easy to reach in to turn things on or off.  Unfortunately, it's not big enough to change the bottle when it's empty, so you would have to design separate access for that.

Regards
John

 

[ccbreder]

My cabinet doors at the homestead are made with flat plywood. 60 years with no warp. It is the quality of wood that matters.
If you have a sufficient hole in the floor of the box, you do not need to seal the box refrigerator tight. A simple hook latch and a hinge will be fine. A bit of gasket will make you feel comfortable then do that. But don't over-think the box. More and most important is to secure the bottle in case of a crash [ that will not be your fault].

 

[GrantRobertson]

One idea I had was to use square aluminum tubing to build the frame of the door to make sure the wood does not warp, as wood tends to do. However, with the hinges I am not sure closing the door would keep things air tight, even with the use of gasket tape / weather stripping.

The best way to keep wood from warping is to: A) Make sure to use good quality, kiln-dried wood that has not been stored outside. B) Seal every surface with a good quality, water-proof finish (even under the hinges). A Marine, spar varnish should be good.

Some will tell you that wood will not warp if it is allowed to breath properly. However, this only applies when both sides of the wood will be in the same environment, which is not the case for your project.

As to sealing around the hinges: If the hinges are on the top of the cover and the seal is on the bottom (or front and back, respectively), then the hinges won't be in the way at all. You could also mortise the hinges flush with the surface of the wood.

 

[flying kurbmaster]

propane is heavier then air so it will sink and go out your hole(s) at the bottom , it is unlikely rise to go out the top, unless you have a major leak and your holes are not copping. On mine I used 5mm ply (luan)with 3/4 x3/4 framing glued and pin nailed, I drilled a couple of 1/2 inch holes through the floor sealed all the joints inside, up the sides and around the base, for the top I used a piece of 1/4 inch ply covered it with alluminium for looks, it is split in half and hinged in the middle, I can lift one side and access the valves, I like to turn it off after every use. The lid fits in snuggly, located at the base of one of my cupboards. To remove the tanks I take the whole lid off, I have two 6bls tanks, I feel safe with this arrangement, I also have a propane snifter/ alarm just in case.

 

[flying kurbmaster]

if you are worried about having a good seal on the top, you could install gastkets and screw the lid down or use latches, to remove the tank then buy one of those round plastic deck access things they sell for boats that screw down, they come if a variety of sizes 4, 5, 6 inches, you could install this just above your valve through the lid.

 

[One Awesome Inch]

Okay thanks for the ideas guys. I think what may work is if I build a lip around the edge of the doorway then build the door maybe 1/8 away from the edge. That 1/8 gap should allow the door to close properly and with gasket tape I should get a decent seal.

At any rate, I think its going to come down to experimentation to see what works best. Checking out some other DIY campervan forums may be fruitful as well.

 

[Oberneldon]

This is a new news article about a propane accident in a camper where the propane fell.

Woman suffers facial burns when fire sweeps through camper at Mansfield campground.

Link: http://www.thesunchronicle.com/news...cle_538b07e4-a1a8-11e4-be2c-4f886d62e91c.html

 

[GrantRobertson]

This is a new news article about a propane accident in a camper where the propane fell.
Woman suffers facial burns when fire sweeps through camper at Mansfield campground.

My heart goes out to this woman and her husband. I hope they or the camp has some kind of insurance that can help them get back on their feet.

What can we learn (be reminded of) from this tragedy?

1. Never move any tank of flammable gas with the regulator or any other fixtures attached.
2. Never attach any regulator or fixtures to a tank unless the tank is secured. This is especially important for larger tanks that could fall with great force.
3. Never store bulk tanks near a residence or a source of heat or flame. Keep them secured in a separate area that is clearly marked with signs warning people to stay well away. (Does anyone know the recommended minimum safe distance?)
4. Never try to put out a fire that is fed by a pressurized tank. A fire extinguisher just can't keep up. Instead, GET THE HELL OUT OF THERE!
5. No matter how much you have gotten used to it or how comfortable you feel, flammable gas is incredibly dangerous and MUST be treated with respect.

It seems that every one of these basic precautions was ignored in this situation.

 

[ccbreder]

Let's try to analyze this very rare accident. 100 pound tank, that is over 150 pounds to be handled. Being delivered (by professionals?). Dropped in such a way to break off the valve assembly, rare occurrence. Didn't this tank have the safety shield protecting the valve? Now we have liquid propane discharged into the air, flowing like water, under the trailer, where it expands to vapor propane, one big cloud of gas.
I take my lesions. Never set a bottle on it's side. Always securely anchor the bottle so it stays put in a crash. Do not use a bottle past it's "use by date". Only use 20 pound bottles at the max. Protect the valve assembly.