On Board Air system

[MichaelOverfield]

Seems I have a strange addiction to truck modifications and additions.. one thing leads to another, or several other things. So I wanted to add rear air springs and level the front with a 2" lift, but that would mean with load the rear would be lower than front, so the air springs were the fix to that. Not being content with just using an external air source, I put together my own on-board air system. The tank is a 6 gallon Al tank, and I'll be running 200PSI at the tank, regulated down to about 120PSI on distribution (adjustable), I added a quick connect for an air hose as well. The air compressor is a continuous duty 200 PSI, and the pressure switch is 165-200. I used a 60A relay mounted near the battery with a control switch in cab, along with compressor run indicator light. I have mechanical gauges on the tank and regulator, with in cab digital indication for the tank pressure, and regulated distribution pressure, as well as indication for each air spring. Also in cab is pressure adjust valves to increase, or decrease air spring pressure, and since I was going nuts with running wires and air hoses I added a switch to select or de-select the air horn, which is activated with the steering wheel horn via a relay. I have some piping still left to do, but I'll put up some of the early pictures and add more as I complete the rest of this system.

 

[mpaulson]

Nice. Are you planning to crawl under the truck to hook up an airline when you want to inflate something? Or are you gonna put a Chuck mounted somewhere else?

The one in the bumper is controlled by an up and down toggle switch that airs up and down an air bag hitch that I use with my RV, but could also be used for an airline.

 

[Ozymandias]

Locks very good!
Good compressor choice by the way.

 

[mfurrh55]

Last compressor I put under truck, froze up going through some snow storms, so I put new one in bed, haven't had any problems in 10 years, the one under truck had snow and ice packed all around it, thawed it out and it was shot, so make sure it has plenty protection

 

[MichaelOverfield]

View attachment 127441 Nice. Are you planning to crawl under the truck to hook up an airline when you want to inflate something? Or are you gonna put a Chuck mounted somewhere else?

The one in the bumper is controlled by an up and down toggle switch that airs up and down an air bag hitch that I use with my RV, but could also be used for an airline.

The coupler is visible between the bed and cab from above, and should be easy to reach.. if not I certainly could move that coupler.

 

[MichaelOverfield]

Last compressor I put under truck, froze up going through some snow storms, so I put new one in bed, haven't had any problems in 10 years, the one under truck had snow and ice packed all around it, thawed it out and it was shot, so make sure it has plenty protection

Interesting, well I will first try to just avoid snow storms! Did you relocate the intake air filter? I have mine under the hood at the highest spot, and that green hose connects it to the compressor. I'm wondering if the freeze up was from moisture in the air side of the compressor.. but putting that intake high and with engine heat under the hood, I'd hope to avoid that fate, should I end up failing in my avoidance of snow storms!

 

[Ozymandias]

Interesting, well I will first try to just avoid snow storms! Did you relocate the intake air filter? I have mine under the hood at the highest spot, and that green hose connects it to the compressor. I'm wondering if the freeze up was from moisture in the air side of the compressor.. but putting that intake high and with engine heat under the hood, I'd hope to avoid that fate, should I end up failing in my avoidance of snow storms!

My intake is on the same spot as yours, never had a problem with it. Runs always as soon as KOEO.

 

[mfurrh55]

Interesting, well I will first try to just avoid snow storms! Did you relocate the intake air filter? I have mine under the hood at the highest spot, and that green hose connects it to the compressor. I'm wondering if the freeze up was from moisture in the air side of the compressor.. but putting that intake high and with engine heat under the hood, I'd hope to avoid that fate, should I end up failing in my avoidance of snow storms!

That might have been my problem , no I didn't have it up high, Thanks for tip, next time I'll know

 

[bcbender]

Had my install / intake on the pass side but similar to yours, never had any issues other than the quick connect on the ping tank rusting up...

 

[Bernie]

That is great, and I am planning something similar.

-Do you have a parts list (and specifically, the tank/frame mounts, and the air chuck in the bumper)

-If you had to do it again, what would you do different?

 

[CBari]

Tell me about your compressor?

 

[mpaulson]

That is great, and I am planning something similar.

-Do you have a parts list (and specifically, the tank/frame mounts, and the air chuck in the bumper)

-If you had to do it again, what would you do different?

The air chuck in the bumper was just a 1/4” brass bulkhead fitting that I threaded the stainless chuck into.

 

[mpaulson]

The coupler is visible between the bed and cab from above, and should be easy to reach.. if not I certainly could move that coupler.

I’d personally be concerned about the dirt and crud that would be in the fitting when I needed to use it being under the truck. The plug I have on my bumper chuck is meant for propane fittings but fits reasonably well in the 1/4 air chuck. Although it does come out a little too easy and with a downward angle like that it’d likely be kind of useless in your case.

 

[DavidC]

I have a rubber boot that I use on the air fitting to keep the dirt out.

 

[mpaulson]

Here’s a compressor mount option for those a who are thinking of adding a system to your truck.
This one is mounted to an aluminum plate that is bolted to the box with four rivnuts that I’ve inserted into the box. This way all I do is disconnect the air lines and wire harness and pull four bolts and move it to the next truck.(this is this units second truck install). This way it’s in the box but tucked under the rail enough to not be in the way of loads etc, yet out of the road spray, ice, dust etc. And it’s easy to work on if needed. The Pacbrake unit is the wireless control for air bags that works with a phone app and it’s been flawless. This way I have no wiring or air lines that I have to run into the cab(easier truck swapping too). I made an aluminium cover to protect it from sun, rain and damage as well.

 

[MichaelOverfield]

Tell me about your compressor?

Viking Horns 200PSI continuous duty, from Amazon:
Amazon product ASIN B07TJ88DK4

 

[MichaelOverfield]

That is great, and I am planning something similar.

-Do you have a parts list (and specifically, the tank/frame mounts, and the air chuck in the bumper)

-If you had to do it again, what would you do different?

I actually made my tank and compressor frame mounts.. going crazy with the MIG welder and reuse of old metal, if you look at the compressor mount, it's part of an old metal car ramp that wasn't up to the task for the front of my truck, and was deformed. I re-used that metal an got better ramps! The tank mounts are reuse from old RV stabilizer jacks, cut and welded to make a mount. I used self tapping bolts from the new RV jacks to mount to the frame. It's important to not drill the top, or especially the bottom of the frame, those are critical stress points, but the center is OK, and that is where my bolts are mounted. I found the air tank on EBay, best option I could come up with after my attempt to make a tank from left over 5 inch stainless from the exhaust work I did last year didn't work so well.. turns out that welding stainless to be leak tight is challenging.. that thing might have been a good bubble stone for a large fish tank.. but not so good as an air tank.. so I just bought the 6061 Al tank that I found on Ebay for a good price. It was sold as a 150 PSI tank, but I verified with the seller that its tested well above 200PSI and should be fine, and I added an appropriate safety valve just in case.

What I'd do different: Would not waste time trying to make a tank.. but kind of covered that already!

 

[MichaelOverfield]

I’d personally be concerned about the dirt and crud that would be in the fitting when I needed to use it being under the truck. The plug I have on my bumper chuck is meant for propane fittings but fits reasonably well in the 1/4 air chuck. Although it does come out a little too easy and with a downward angle like that it’d likely be kind of useless in your case.

Agree, I'm looking for a suitable cover for that reason. Might have to make one, I've been surprised they are not easy to find, we had them all over the place on the Submarines I've been on to cover the EAB (Emergency Air Breathing) air connectors when not in use.

 

[Ozymandias]

Check for a battery box for boats or RV.

 

[MichaelOverfield]

Somehow it seems the air horn picture did not make it earlier.. here it is.