Another project!

So I've bought this:

It is a Viair 485C and is capable of 200psi at a flow rate of 25l/min and a 100% duty cycle.
It's also supposed to be quiet according to their website (it isn't, not compared to the standard compressor anyway).

Should be good, if I can make it fit that is:

I'll need to redesign a complete new mounting and housing for the compressor and the valve block. Fun!

Has anyone come across a 3D CAD model of the valveblock? Or even a dimensioned 2D drawing?

Watching with interest. I do think the modest duty cycle of the original coupled with the increasing quality doubts of available replacements will make Viair and similar swaps more interesting, especially if coupled with on board air. Can't help with the dimensions I am afraid, but there are an increasing number of 3D scanners out there many someone will create a model for you?

JLimmelman wrote:

Has anyone come across a 3D CAD model of the valveblock? Or even a dimensioned 2D drawing?

I have never seen a 3D CAD model or even an engineering drawing of the valve block.
The outside is a fairly simple shape, just rectangular blocks, so it should be possible to draw an approximation, to aid fitting it into a case for example.
However, the inside of the valve block is quite complex, with all the ports and internal passageways. To come up with a model showing all that detail it would have to come from official sources I think.
3D scanners are getting better all the time, so that maybe the route to get a scan of the outside of the block.

Just use a spare valve block & driver pack assembly, and make a larger EAS housing ? You can use the existing hole pattern as template for the new housing.

You might need a louder stereo to drown out the pump noise !! BTW, what's that blue thing that looks like a motor ?

Yes, I was pushing my luck hoping someone had a CAD model or drawing. I don't need the interior ports, basically just a "space claim" model around which to model the box.

I'm busy with the process of drawing sucah a model using my spare valveblock as Pete suggested. Progress so far:

I'm hoping that adding some decent sound deadening material designed into the new enclosure will help mute the noise of the compressor. We'll see!

The blue motor mounted on the left front strut tower is an ARB air compressor. Currently being used for tire inflation etc. but it is also plumbed in parallel with the EAS compressor with a one way valve. I can switch on to run when the EAS compressor runs as a backup if the EAS compressor might fail.

Is this an upgrade or to mask other faults? I’ve only run out of air when I had a leak…..

Nope, EAS works beautifully for normal use.
I had the compressor struggle to keep up on one 4x4 trail where I was cycling between standard and offroad height multiple times. Not a usual use case and I wasn't surprised.

The upgrade is so that I can use the onboard air reservoir for tyres, pressurizing a water tank etc.

Sounds like a good plan!

I do remember mine giving up on an off road trial but put it down to the leaks I discovered. Maybe I would have run out of air anyway !

The only reason I can see for changing/upgrading the compressor is if you have fitted Arnott Gen III's.

The extra 2" of lift that Gen III's give takes a lot of air. It quickly robs the tank when you put it on high. Not a problem if you are up to pressure and you go off road. One lift is fine. The problem arises when you go back on tarmac then go off road again. If the tank pressure has not built back up in time, it can't get back up.
FYI when I have bench tested rebuilt compressors with new seals, it took 6 mins or there abouts to get the accumulator from zero up to pressure. This was on the bench, not the car.
I personally like Marty's idea to fit two original type compressors. Like an installed spare with the ability to switch either one or both together.

Spent some more time modelling up the valveblock.
At last!

And next to the Viair compressor:

Would be great if I can get the compressor mounted sometime this year!

Wow !

This looks great!
Did you get it mounted I'm thinking tell us how and show us some pictures please :D
I thinking of doing the same mod sice it gives kind of a good feeling with a 100% duty compressor on board ;)
Would you mid sharing your CAD files (I'm using fusion360 but .stp .step files could also work).

Kind regards/Stefan @stockholmviews.com

Hi Stefan,

Nope, not mounted yet, the compressor is still in it's box in the corner of my office, but the project isn't dead yet either.
So the current direction is to retain the stock compressor in it's stock location, and rather mount the VIAIR nearby. This allows me to use the stock compressor (quiet) to operate from say 8-10bar and only have the VIAIR (loud) come on if the pressure drops below 8bar (values will be finalised when I start testing). I'm thinking this will give me a best of both world's scenario where in traffic, around town etc the stock compressor will handle low volume air duties like cycling between standard and highway height, and it will do so quietly. Large volume air duties like pumping tyres, lifting from access to standard will be handled by the VIAIR.

The idea above necessitates some changes to the driver pack, which I am busy redesigning anyway. I'll add control for the 2nd compressor, a pressure sensor (not just a switch, so that I can use software to adjust the limits) as well as a way to manually control the valves.
The manual valve control is something I want to add so that I can manually adjust the suspension height and lock it in that height for camping (rooftop tent).

The new VIAIR location is still being discussed, but currently it looks like it will live on the left chassis rail, forward of the left from airspring mount. Basically under the steering fluid reservoir. It'll have some heat and mud shielding around it and should be easily removable if I am any good at bracket design.

I'll email you the CAD models shortly.

PS: I have a bit of a deadline for this project now, so hopefully it'll actually get done. We are doing a desert river exploration trip early in next year, and the pneumatic system needs to be done by then so that the air lockers and vehicle levelling works as I want it.

stefan63 wrote:

Would you mid sharing your CAD files (I'm using fusion360 but .stp .step files could also work).

Kind regards/Stefan @stockholmviews.com

I tried sending you the CAD files, but it seems your email address is blocking it?
This is the response I got:
Message blocked
Your message to Stefan@stockholmviews.com has been blocked. See technical details below for more information.
The response from the remote server was:
550 5.1.1 Unknown recipient

Cheers,
Justus

JLImmelman wrote:

stefan63 wrote:

Would you mid sharing your CAD files (I'm using fusion360 but .stp .step files could also work).

Kind regards/Stefan @stockholmviews.com

I tried sending you the CAD files, but it seems your email address is blocking it?
This is the response I got:
Message blocked
Your message to Stefan@stockholmviews.com has been blocked. See technical details below for more information.
The response from the remote server was:
550 5.1.1 Unknown recipient

Cheers,
Justus

Thank you!
Try stefan63@gmail.com instead!
Your idé and project sounds nice looking forward to the folow up report when you have tested you new system.
stockholmviews.com is my website and you can find some P38 related stuff there if you find it interesting (https://www.stockholmviews.com/p38/).
I'm also working on a alternative pressure/over temp contoller based on a arduino nano some info on that can be found in my FB group https://www.facebook.com/groups/RRP38. Kind regards/Stefan

Perfect, mail sent.

I checked out your site, some interesting content there. I'll browse more at a later stage.
I don't do social media, so sadly no way for me to check out your page.

Cheers,
Justus