The Smell of Molten Projects in the Morning

Ed Nisley's Blog: Shop notes, electronics, firmware, machinery, 3D printing, laser cuttery, and curiosities. Contents: 100% human thinking, 0% AI slop.

Tag: Repairs

If it used to work, it can work again

  • Water Heater Drain & Flush

    Flushing with Y hose connector
    Flushing with Y hose connector

    For reasons that aren’t germane here, I’m responsible for two water heaters. Having just replaced one of them, I figured I should do a preemptive drain-and-flush on the other and check its anode rod.

    In principle, you just hitch a garden hose to the drain valve, turn it on, and flush the sediment right out of the bottom. In practice, it doesn’t work that smoothly, as the valve has a teeny little opening that instantly clogs with grit.

    The first step is to shut off the water, open the drain valve, and disconnect both flexible couplings at the top of the heater. You will move the heater a little bit during this operation and that will cause the flexy connectors to leak, maybe just a little bit, but enough to cause Bad Things to occur.

    In the past I’ve used a Y hose connector with a homebrew double-female adapter to blow water into the bottom of the heater; the hose runs to a nearby sink with a male hose thread on the cold-water faucet. The two teardrop-shaped black handles on the Y adapter are ball valve handles (crappy valves, but good enough).

    It goes like this:

    • Close the Y hose valve
    • Turn on the water at the sink
    • Open the water heater drain valve
    • Open the Y drain valve
    • Watch a brief piddle of water hit the bucket
    • Close the Y drain valve
    • Open the Y hose valve to blast water into the tank
    • Close it again
    • Open the drain
    • Repeat as needed

    With any luck, you won’t have that much sediment and the drainage will clear after only a few iterations. That didn’t happen here…

    Water heater drain valve parts
    Water heater drain valve parts

    The next step is to apply a strap wrench to the drain valve, remove the cover and core, and see if the larger opening will produce more flow.

    Note that the drain valve, at least on this Whirlpool heater, is basically a coarse-thread plug that depends on a rubber disk to seal against the valve body. I’d really rather have a full-flow ball valve down there instead of this piddly little thing.

    it is possible to replace the drain valve entirely, but the last time around I applied far more force than I thought prudent to the plastic valve body and got exactly bupkis in the way of rotation. Not wanting to break the damn thing off, I gave up.

    Valve cleanout with copper wire
    Valve cleanout with copper wire

    Anyhow, with the guts of the valve out of the way, the flow was still fairly weak. I rammed a copper wire up its snout and dislodged a truly disheartening amount of crud. The opening kept jamming shut, which meant there was a great pile of sediment atop the opening, so I spent quite  while wiggling the wire to keep the water flowing and the grit emerging. The pic at at the bottom shows some of the pile; there’s a heaping double handful of sediment on that shovel.

    The bottom of the tank is flat, with the valve pretty much flush with the bottom. That means you’ll leave a huge pile of sediment inside unless you swish some water around. That, of course, will clog the valve. Repeat until tired.

    When you go to put the valve back together, don’t be surprised if it doesn’t seal. Tighten the cap, put a hose plug on the outlet, and move on.

    You can tell by the color of the water that Something Is Not Right inside the tank… more on that tomorrow.

    Some of the water heater sediment
    Some of the water heater sediment
  • Tour Easy: Tightening the Coolback Seat Lace Cord

    Every now and then I notice the pedals are getting further away on my Tour Easy recumbent, which means it’s time to snug up the seat lace again. The lace cord has a Kevlar core, so it’s not very stretchy, but over the course of a few thousand miles either it stretches or the seat mesh relaxes.

    Here’s the only tool I’ve found that works for this purpose:

    Stanley 82-113 Hook Tool
    Stanley 82-113 Hook Tool: "The Hemorrhoid Picker"

    That’s what a friend calls his, anyway.

    It’s from Stanley and not in their current website listing, but they do offer the 78-393 – 4 Piece Hook and Pick Set, which looks to have a tool sporting the same hook end with a different (and much smaller) handle. IIRC, I got this one several-many years ago at Wal-Mart; maybe it’s a special-issue part number just for their shelves?

    What you do is work your way from the bottom of the seat lacing on one side all the way to the top, pulling out the slack as you go. At the top of that side, pull the accumulated cord into the knot, then start at the bottom of the other side. When you’ve got both sides pulled taut, knot up the slack again and you’re done.

    Needless to say, you can give yourself a King Hell puncture wound with that thing…

  • Digital Caliper Disassembly

    Caliper Back Side - Label Removed
    Caliper Back Side – Label Removed

    Just in case I spill a sticky liquid on the caliper and must disassemble it again…

    This was a relatively inexpenive, but not dirt cheap, caliper that has worked fine all along, apart from the issue with the thumb roller frame.

    After removing all the obvious screws, taking off all the various doodads, and extracting the sliding jaw, it still doesn’t come apart. The trick, as always, is to peel the label off the back side to reveal the five crucial screws that secure the electronics package to the metal scale.

    These screws don’t have the best heads in the world, but a #2 Phillips driver, solid pressure, and steady torque gets them out. All but one of the screws are pointed; the one in the lower-left corner (as above) is a machine screw that, I think, ensures a good electrical connection between the metal frame and the electronics package.

    Caliper Disassembled
    Caliper Disassembled

    With those screws removed, the electronics package pulls off to expose the innards. Note the cough delicate hand-forging that secures the tang to the back plate.

    The schmutz on the far right matched up with a similar patch of rust on the sliding scale. Some TopSaver rust treatment applied with a scrubbing pad reduced the problem to mere discoloration; the rust wasn’t all that deep.

    Reassemble in reverse order, with dabs of lubricant on the obvious wear points along the way. The thumb roller must go on after securing the electronics package, not before.

  • Slow Leak Detector: Tissue Paper

    Tissue-paper leak detector
    Tissue-paper leak detector

    When you make a plumbing joint with screwed compression fittings, there’s always a question of whether you’ve tightened the nut enough to make a good seal. The fittings come with copious warnings to not overtighten the nuts, which means I tend to undertighten them.

    It’s easy to spot a major leak or a trickle, but what about a very slow ooze on a hot water line where the drip will evaporate before you notice?

    Fold up a piece of tissue paper and secure it around the joint with a wire tie. Come back a few minutes / hours / days later: it’s easy to tell if the tissue has ever been wet, because its texture will be dramatically different.

    Having just replaced a water heater, the subject of leakage is a hot topic around here…

  • Whirlpool Water Heater “Lifetime” Warranty: The Good and the Bad

    So our 6-year-old Whirlpool electric water heater tank failed and dribbled water on the floor. Fortunately, I spotted the leak before it flooded the basement: I look at the heater just about every time I venture into the Basement Laboratory Electronics Wing. Judging from the mildew & fungus growing on the wooden base I built for it, though, I haven’t been doing a good job of walk-by inspecting. In my defense, the visible wooden edge is 3/8″ thick below the dark rim of the heater.

    Grit drained from tank
    Grit drained from tank

    I turned off the inlet & outlet ball valves, flipped the breaker off, routed a garden hose out the door, laid the end in an old cake pan, and drained the tank. The pan collected a fair amount of rusty grit (and more washed down the driveway), which means the glass-lined tank was suffering from internal rust.

    A call to the Warranty Hotline produced an Indian-subcontinent accented voice, who told me that I had to get a licensed plumber to tell them that it was, in fact, rusted out. “Any plumber in the phone book will do”, he said, “Just have them call this number and we will verify the situation with them.”

    My back of the envelope, confirmed by friends, is that it’d cost about $150 for a plumber to drop in. Oh, and this was on a Saturday morning, which means it might be a while later and bit more expensive than that. Paying somebody $75/hour to wait on hold didn’t seem attractive.

    A new heater of the same general nature is $400, give or take.

    Soooo, in round numbers, I’d be spending half the cost of the “free”  replacement just to find out if Whirlpool would honor the warranty.

    I was ready to just cut my losses and buy another heater when my friend Aitch suggested two simple alternatives:

    • Call the warranty line again, point out that this is the Internet Age, and offer to send them pictures of the problem, along with a statement that I was being truthful.
    • Spend the $150 to ship the dead heater to the office of the Whirlpool CEO with a note describing the situation

    I picked the first option and had a brief conversation along these general lines:

    • paying nearly half the price of a new heater for an “evaluation” is absurd
    • the leak was near the top; even the caps over the heating elements were rusted
    • the grit shows that tank has internal rust, so it’s not external corrosion
    • I’ll send pictures anywhere you want

    Much to my astonishment, the pleasant voice gave me a replacement authorization! No pictures needed.

    Knock me over with a feather…

    So I hauled the corpse back to Lowe’s, swapped it out for a new one, and away I went.

    Now, it’s worth noting that the new heater has a 12-year tank warranty, not the lifetime one that came with the original purchase. Given my experience with the first one, we’ll see what happens; I suppose they learned how expensive a lifetime warranty can be.

    Overall, a pleasant surprise, although the initial presentation wasn’t encouraging in the least.

    Memo to Self: Don’t ask, don’t get…

  • Blender Bearing Repair: Round Two

    Blender impeller and bearings
    Blender impeller and bearings

    It seems the bearings in our cheap blender last about a year, even if we don’t put the impeller in the dishwasher.

    The top bearing, the one nearest the impeller (on the left in the pic), developed detents, which says at least one of the balls has failed.

    Both bearing housings are rusty; water has no trouble getting past the flexible seals at each end. As they’re not immersion-proof, I assume the water has little trouble getting past the shield rings on either side of the balls.

    I replaced both of them, squeezed some silicone stopcock grease above the top bearing in the vain hope of excluding liquids, and we’ll see what transpires.

  • Sears Kenmore Dishwasher Sound Deadening Sheet: On the Move!

    Sound deadening sheet jammed in door spring
    Sound deadening sheet jammed in door spring

    Our dishwasher door started making an odd gronking noise when it was opened or closed. It had done this before, so I knew what was going on: one of the sound deadening sheets inside was creeping down around the enclosure and jamming itself into the spring.

    It turns out that a layer of adhesive holds the sheets in position and, in hot weather, the weight of the sheet pulls it right over the edge. They’re made of asphalt or something equally black and sticky and heavy, just what you want to dampen vibrations on those big unsupported enclosure sides.

    Oddly, this is the only sheet that’s on the move. The others are pretty much stuck where they started. I don’t know if it’s hotter on this side or what’s going on.

    Sound deadening sheet creepage
    Sound deadening sheet creepage

    The situation was much worse the last time; I had to hack off a huge chunk of the sheet that had buckled around the right side of the dishwasher under the fiberglass insulating blanket. The spring was pretty much encased in shredded asphalt. Not a pretty sight.

    This time the sheet traveled only a few inches, just enough to hit the spring with the door about half-open. I broke off the offending part, crudely flattened the rest, and moved the entire sheet back up to the top of the enclosure.

    A few strips of duct tape should hold the sheet in place until the heat relaxes the bent areas and improves its contact with the enclosure. I hope that, with most of the remaining sheet on top, rather than hanging off the side, it’ll stay in place until the dishwasher goes casters-up for the last time.