Propane box, storage/transport ideas?

camper101

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I’m wondering if you have any advice on propane transport/storage. I have a FWC shell, and somewhat recently learned that you shouldn’t keep the propane in the living space with you (obvious to some of you, I’m sure). I now have a furnace, so the propane needs to go somewhere.

My goal is to be substantially safer than I used to be. I realize I simply can’t make it as safe as if I had the factory propane box installed, but I’d like to make a nice dent in things. In the past, we used to keep the propane tank in the camper while running our Wave 3.

I’d like to build a propane box inside the camper, and I understand this is how they do/allow things in Europe. I’d build a box with plywood, seal the corners, and cover the entire interior with fiberglass to make it airtight. Then I’d have some kind of airtight lid (maybe with rubber weatherstripping that latches down firmly). I’d drill holes in the bottom of the box that pass through the camper floor and vent to the outside (at the rear of the camper where it hangs out past the truck bed, maybe 2 1”hole saw holes). I’d also put a propane detector right next to the box. I can run the hose outside of the camper, so there are no additional holes in the box or connections inside.

Again, it’s not perfect, but I’m curious if it is SO imperfect that it’s not even worth my time and I'd just get a false sense of security. Like, I might as well just keep the propane in the living space with us and save myself the hassle… I guess I want to protect against smaller propane leaks, when things heat up or if the regulator leaks a little. I don’t know that this would protect against catastrophic high-pressure releases, but I (really) also don’t know if those are more or less likely than smaller leaks. I also realize that it’s important to focus on the magnitude of an event, not just the probability of it…

What about mounting it outside? I’m semi-open to this idea, but I don’t like the idea of the tank being there all the time and sticking out, and I’m not sure how I’d connect/disconnect the hoses when I’m not using the furnace. It doesn’t seem like a good idea to drive around with a hose coming off the tank (mounted high on the rear wall), and I can’t really imagine where the regulator would go since that of course needs to be outside.

Thank you.

Edit to add: BTW I have the sofa on the passenger driver's side, so installing a factory-like propane box where it usually goes won't work unfortunately.

Also edited to say: I plan to run the furnace while the propane is in the propane box (which is in the living space), which might not be clear from my post title.
 
What was imperfect about your original idea? As long as its sealed off and vented you're good. Just looking for giving the gas a patch of least resistance out. I wouldn't run the hose outside the camper though, just caulk up the pass through or use a bulkhead fitting.
 
pods8 said:
What was imperfect about your original idea? As long as its sealed off and vented you're good. Just looking for giving the gas a patch of least resistance out. I wouldn't run the hose outside the camper though, just caulk up the pass through or use a bulkhead fitting.
Thanks pods8. I think (hope) it's a decent approach, but I'm not an expert on this stuff. The main problems seem to be:
- There's no upper vent to supply airflow for draining propane out of the box -- only bottom vents (but they only have bottom vents on boat propane lockers, so I figure it can't be that bad)
- Getting the lid to be airtight will be a challenge
 
I store it under the bench next to the open turnbuckle port. I haven't detected any propane inside the camper using that technique but I'm not an expert.
 
I wouldn't think the plywood box would need to be glassed if it was glued and screwed and the hole for the hose to pass into the cabin had a tight fitting grommet.


Good luck finding the extrior door for the propane hatch...I've been looking for a long time while researching for my shell model build out. Gas doors? Water doors? Exterior shower doors? everywhere. Propane doors with the bottom vent? unobtanium.
 
contento said:
I wouldn't think the plywood box would need to be glassed if it was glued and screwed and the hole for the hose to pass into the cabin had a tight fitting grommet.


Good luck finding the extrior door for the propane hatch...I've been looking for a long time while researching for my shell model build out. Gas doors? Water doors? Exterior shower doors? everywhere. Propane doors with the bottom vent? unobtanium.
Yes it's amazing how hard it is to find anything for a propane box aftermarket. The closest I've found are propane lockers for boats, which aren't cheap, and aren't the right size.

My hatch/door will open into the living space of the camper, so I think it will have to be a lid on the top of the box (that way, just in case it's not airtight, any leaked propane will hopefully settle to the bottom and drain out).

I've been thinking of trying to "double-seal" the door: I'd have rubber weatherstripping (like a refrigerator door) compressed with latches, and inside of the box there'd be another seal with foam weatherstripping. Not sure how to explain that or what you'd call it...
 
Could have a sheet metal shop build you a metal box. Specify that it needs to be gas tight.

Look at Trimlock.com for bulb seals. McMaster.com carries their stuff.

Might have a look at Austin Hardware for latches etc.

Fasten some small grid size wire mesh down over the vent hole to keep stowaways out.

Buy one of the doors that you can find for sale and have it louvered. Some sheet metal shops can do this, or try looking in your local hot rod community for someone with a louver press. I can recommend someone in the 93002/3 area. PM if that helps.
 
Thanks Thom those seals look like the real deal. These are the kinds of things I don't know about. That inspires me to get some quotes from fabricators just to see.

FYI for anybody who wants a crappy diagram of what I have in mind, here it is. The lid is flipped open because I'm getting the tank refilled in this shot. The hole is where the leaked propane would drain out. And of course it'd be installed straight, not all crooked (unless I do it myself...).
img_83159_0_eab885966a3bc20c94f2c1027bd34095.jpg
 
contento said:
Good luck finding the extrior door for the propane hatch...I've been looking for a long time while researching for my shell model build out. Gas doors? Water doors? Exterior shower doors? everywhere. Propane doors with the bottom vent? unobtanium.

I just picked up a normal RV hatch door for mine, they aren't air tight even without vents and my box is going to be totally sealed off from the camper so I said good enough.
 
Do you have an air space under the camper while it is in the bed? Our Phoenix sits on a rubber bed mat, so that vent hole would not work for us.
 
ntsqd said:
Do you have an air space under the camper while it is in the bed? Our Phoenix sits on a rubber bed mat, so that vent hole would not work for us.
Yes, the back of the camper hangs out over the end of the bed. The hole is kind of above the bumper (maybe 4-6 inches above?), but the bumper slopes down/away from the truck so I'm comfortable enough with that.
 
Espresso said:
Is there such a business as a RV wrecking yard? They would have what you need.
I may just have to go that route, but I've been assuming they'd only have side-opening exterior propane boxes, and I'm hoping to have something that will look more or less decent for the insterior of the camper. Might be worth a look though.
 
For anybody following along, I'm now thinking of doing this with plastic. I'm not feeling a ton of confidence about the welders on Craigslist, although it's partly my fault I haven't spent much time figuring this out with them.

Somebody suggested Colorado Plastics, where I can get materials very cheap through the leftovers bin. Then you basically glue the stuff together into a box (but it's stronger than glue... apparently this is called solvent welding?).

I think the sealing lid will be made by a silicone layer that is compressed as you screw the top down (using a flange on the outside of the box and thumb screws or wingnuts).

A thick plastic like 3/4" or more will hopefully be sufficiently strong, and I believe it's basically what they use on boat propane lockers.
 
I went to a local plastic shop and discussed my options. They suggested 1/4 inch ABS plastic (very strong, drills well, inexpensive) for the box.

In their junk bin was the box shown below. This is almost exactly what I have in mind, only the dimensions are different: a box with a lip around the edge. I'll get an extra sheet for a lid, and keep the box closed by screwing the lid to the lip (perhaps only 3 sides will stick out like that so it can sit against the wall). The seal will come from a flat layer of silicone (somebody told me to lay down two layers of tape, put a bunch of silicone down, and scrape along the tape with a straightedge to make a flat layer of silicone).

They can also build the box. I just guessed on dimensions, but for a 5 lb tank box it'd probably be $30 for materials and $70 for labor. Given my skills/equipment/pace, I think I'll have them build it.
 

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After building a prototype with cardboard, I don't want the lip that sticks out like the box above. Instead I think I can have some material sticking IN to the box just at the corners. I'll screw the lid on using those corner pieces.

The box has some excess room for regulator and hosing, so losing an inch at each corner shouldn't block the tank from getting in and out.
 
Thanks Captm that is outside the box. I just went out and tested with our toilet (it's a 5 gal gamma sealed, with poo bags of course) and it's not bad at all, but doesn't fit as nicely as I'd like -- sticks out an extra 2 inches or so right at the door, and the hole would have to be farther towards the front where it's barely off the truck bed. I really appreciate the simplicity and cost of that approach though. Those buckets are a great fit for an 11lb tank.

Never knew what a mushroom head was until now, but I might need one.

Thanks again
 
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