dc fridge conversion - isolde part 1

This is a project to convert Isolde's factory thermal siphon refrigerator to a modern 12V DC only. The new refrigerator adds more than double the capacity and can for he first time keep food at the needed temperatures. Together with the refrigerator conversion I will also be upgrading the audio system and the axillary battery system. The upgrading of the audio system will make room for my planned location for the batteries under the bench seat.

this is the factory configuration which has a small thermal siphon propane (plus 12Vdc and 120Vac) Dometic refrigerator; it was from decades before efficient DC compressor was developed

fast forward 26 years later, the second generation of these fridges are very affordable and good; this one is Truckfridge TF49

not crazy about the purple LED light inside

some nominal current measurements

ranges around 2.5A to 3.3A; start up surge is much higher

this little fridge has no problem turning into a freezer at all - i checked the temperature near the bottom with a thermocouple thermometer

I have been testing the refrigerator for many months now to be sure it is what I expect before committing to this major enhancement. I have been using it as my overflow refrigerator at home.

Before the installation I am painting the outside to the color close to the Westfalia's factory cabinet trims. This involves painting plastic parts as well as metal. The fridge is designed to accommodate a custom door insert. The obvious choice is to find a piece of plastic laminate of the same or similar color as the factory cabinet. A precise match would be a tall order due to some sun fade, and the unlikely to procure a close enough color.

I decided to explore to have the door insert of unrelated design. I want to add a bit of jazz by making it a highlight.

I found a range of Formica sample chips that has abstract design. It would turned out all but 2 are from the company's 100th years anniversary special edition.

here i set them against the interior table

With the door insert still very much up in the air, I set out recently to paint the parts.

the parts to be painted are disassembled from the fridge

 i remove the interior light to see what kind of LED bulb it is planning to replace it with one that is warm white

 all the plastic parts are scrubbed with 3M grey abrasive pad

i was happy that i could cleanly remove the ugly truckfridge label from the handle

masking the fridge and the door took a lot of work

 the adhesion promoter and the grey top coat

i primed the metal parts and spray the plastic parts with a clear adhesion promoter

 i took shelter from the hot afternoon sun - shade tree autobodyman

with the door plastic trims painted i set the Formica chips there to visualize