DIY All-in-One Diesel Heater Unit in a Ridgid Case

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Crafting your all-in-one diesel heater unit using a Ridgid case from Home Depot is not only a cost-effective solution but also an efficient way to bring warmth to various spaces like tents, campers, garage or other environments. In this step-by-step guide, we'll walk you through the process of assembling this project using the Ridgid case and incorporating 3D-printed components.

Supplies

Ridgid case from Home Depot

2KW Diesel heater

Thru Hull Exhaust Fitting

60mm to 60mm connector

90mm 12V computer fan

2-inch ABS/PVC pipe

Exhaust wrap

Electrical components (SEA and XT90 plug)

3D printed parts found here ; https://cults3d.com/en/3d-model/various/all-in-one-diesel-heater-unit-in-a-ridgid-case

Step 1: Positioning and Marking

Begin by placing the 2KW diesel heater inside the Ridgid case. Use a Sharpie to mark the heater hole on the case, ensuring you find the center before drilling a pilot hole. Proceed to drill a 2.5-inch hole from the outside of the case.

Step 2: Installing Thru Hull Exhaust Fitting

Flip the Thru Hull Exhaust Fitting upside down, center it, and drill screw holes. Once done, mount it with the included gaskets after drilling a 2-inch hole.

Step 3: Creating a Hot Air Escape Hole

Drill a 2 or 2.5-inch hole between the two previously drilled holes to allow hot air to escape. Position it slightly to the left of the center since the hole for hot air from the diesel heater enters the center third of the case.

Step 4: Intake and Fan Openings

On the opposite side, drill two 2.5-inch holes at the centers of the top third and center third for cold air intake and the fan.

Step 5: Marking and Drilling the Divider

Reposition the diesel heater back in the case with the divider. Mark and drill a 2.5-inch hole on the intake side; you may need to slightly enlarge this hole with a knife to fit the intake connector. Proceed to drill two evenly spaced 2-inch holes on the divider for air passage and remove the bottom corner for a wire passage.

Step 6: Altering the Mount for the Diesel Heater Unit

Assemble the metal plate, making any necessary marks and bends. Securely mount the plate to the diesel heater unit.

Step 7: Mounting the Diesel Heater

Screw the 3D-printed spacer into the hot air exit and insert the 60mm to 60mm connector into that hole from the inside. Trim the flange inside the box to approximately 3/4 of an inch and attach the hose that came with the heater unit to connect the two pieces together using clamps. Drill holes through the bottom of the case to mount the diesel heater. Attach the 3D printed intake connector and an 8-inch long piece of 2-inch ABS/PVC pipe through the designated intake hole.

Step 8: Incorporating the Computer Fan and Grates

Mount the 90mm 12V computer fan and 3D-printed fan grate on the designated fan hole. Additionally, add a 3D-printed grate to the airflow exit hole on the opposite side of the case.

Step 9: Installing Air Filter, Fuel Pump and Exhaust Pipe

Mount the fuel pump onto the 3D printed 30-degree angle mount and secure it to the bottom of the case. Wrap the exhaust pipe with exhaust wrap and attach both sides with muffler/tailpipe putty. Finally, secure the intake air filter using the 3D printed mount or double-sided tape.

Step 10: Connecting Fuel Line and Electrical Components

Run the fuel line and connect the electrical components, utilizing SEA and XT90 plugs or alternatives compatible with your camping gear.

Step 11: Finalizing and Testing

Attach the 3D printed foot to the back of the case and the "DIESEL HEATER" nameplate to the front. Insert the grate into the intake tube and the removable cap to the exit tube. Trim the lid if necessary to prevent wiring from the heater unit from rubbing on it. Ensure all components are securely mounted and give the diesel heater a test run to confirm its functionality.

Safety Measures:

• Always operate the diesel heater in a well-ventilated area to prevent the buildup of exhaust fumes.
• Regularly inspect all connections, fuel lines, and electrical components for any signs of wear or damage.
• Keep flammable materials away from the heater during operation.
• Follow the manufacturer's guidelines and safety instructions for the diesel heater.
• In case of any unusual odors, smoke, or malfunctions, immediately turn off the heater and seek professional assistance.

By following these comprehensive steps, you'll have successfully created a portable diesel heater unit housed within a Ridgid case, providing warmth and comfort in diverse outdoor environments.