DIY Chiller Project

Step 3: Modify and Reuse the Fridge-cabinet

We decided to re-use the fridge-cabinet because of its steel casing and given good isolation as well.
Simply put, we decided to turn the frigde on its back. You can't do this with the compressor of course, so the 'sled' on which the compressor sits moved as well.

To use the cabinet, we had to change/do several things.
1. The thermostat had to move.
2. Change wiring (but re-use because most of it goes through the fridge and isolation, cutting that away would void the idea of using it in the first place.)
3. Fill the holes.
4. Check the pipes of the cooling-element. (The guys found a small hole in one of the pipes. And darn, this is a small dorm-fridge so these pipes are inside the isolation between inner- and outer-wall.) Damaged from the earlier setup with hose and air.
Lesson to be learned here. If there's no 'pipe-frame' on the back of your fridge then sure it is inside your fridge-wall. Drill holes only in the door if you're not sure about the location... (or switch on the fridge, let it run for a while and you'll find the area's they are located getting very hot).
5. Putting the pipes in place for the hose.
6. Patching up the areas with 2-component filler.
7. Bend the in/outlet copper pipes to re-connect later to the compressor. (Many have said it before, once more....Do this very carefully to make sure that especially the very thin lines dont break or flatten on the bend, blocking the flow of coolant.

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Step 3a: Modify and Reuse the door

Meanwhile, the door has been taken apart as well.
The plastic with its bottle holder and stuff has no function anymore.
- get the screws out (covered under the rubber seal)
Don't damage the rubber-seal. Reuse it later. It has a magnetic strip in it, good enough to keep the lid in place on top of the chiller.
- take the plastic away
- Put a plastic waste-bag on top of the exposed isolation material.
- Put the seal back on, now using the screws throught the rubber seal (inner most part.
- Cut away the excess plastic waste bag around the door.
- Ready for use.

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Step 4: Assembly of the compressor and other parts.

All ground-work done, we used two metal L-shape brackets to reconnect the compressor-sled to the fridge.
As mentioned before the fridge went on its back.
So the compressor-sled turned 180 Degrees and reconnected to the old bottom of the fridge. (which now is one of the 4 vertical sides of the fridge...mind my description, hope you'll understand it with the pictures.

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Step 5: Filling up the gas...

Ok, all parts in place. We're pretty much done except to fill it up again.

Took some time, to pull out the air, get it replaced with cooling-liquid but it went smooth and boy it's running well...

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Step 6: Connect, fill and running

Last step. filling it with water.
Advise not to fill it up covering the element completely. (I am not sure why, but the 2 guys who helped me work on fridges and aircon every day...so I don't question their knowledge on it.)
But after connection and filling, a power-head added and everything running now.
Very happy with it.
Temperature before: 30'C (that is... anywhere between 30.0 and 30.9)
Knocked off 2'Celcius for what it looks after 24 hours...
(does not look like a record-setter, but it was running 24 hrs before the change, and now I run it about 12 hours only (together with the CO-2, same timer.))

Still room for improvement though:
The tube is relatively thick and not optimal for cooling.
So eventually, I'll replace that with either a thinner tube, or it will become a copper pipe. (fresh-water tank, wouldn't touch copper pipe for a SW-tank...)

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To the bean-counters around, (and including myself, most of us will have to count every bean on a very nice but expensive hobby...)
The cost for the fridge: THB 1,400.00
Cost for hose: THB 230.00
Aircon-guys: THB 1,000.00 (including all used materials)
9 Singha Beers: THB 224.00
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Total Cost: THB 2,854.00 ~ USD 82.20 ~ EUR 57.81

Improvements/changes made, will upload them in due course.
Let me know if you have any questions....and have fun doing this project.
Will be very curious to other approaches/takes on this.

Luc
 
First day of readings, steady temperature most of the day-time. 27.5 ~ 28.5'C...
Only late afternoon, it will edge out around 29.0 - 29.5'C
Switched off for the night (9pm) Timer on 7am...
My tanks are outside, mentioned it earlier, average temperature day-time is 35-36'C.
So given that it is a large tank and in very hot conditions, this small fridge is doing a marvelous job.
I've put a server-fan on the compressor, to make sure it looses most of its heat.
And I've put the powerhead to pumping water from the big compartment (where the hoses are) and put a small piece of hose from its outlet to pump it into the freezer compartment. That made some small improvements as well.

Can imagine that a setup with maybe 30-50G tank would work perfect to keep your temperature in the 26-28'C range @ almost no cost.
 
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