Webasto Packout Heater Components

OVERVIEW

This is a self contained diesel heater set up that can be used for heating tents, RV's , truck campers, ice-fishing huts and more. This is a paid file because of the countless hours I've spent designing and tweaking these parts, plus it's just a small investment into a much larger project. This is a collection of files that you need to print to assemble your very own webasto packout heater. This assembly makes use of a Milwaukee packout box (or similar), a diesel Webasto heater, these printable components and few electronics. Many people have made this in the internet and I wanted to make make own. Here is a great example. I designed these files meticulously in Autodesk Fusion, and am sharing the model files. The model files include OBJ's for easy printing and an accompanying f3d file in case you want to make some modifications. 

PRINTING TIPS

• I printed these in Fiberon PA6-CF20 because of its excellent strength, resistance, and most importantly a heat deflection temperature of up to 215° C! 
• At least 3 perimeters, 20% infill, scarf joints to ensure smooth contours. 
• NO SUPPORTS NECCESARY

REQUIRED MATERIALS

• 2x “webasto_COUPLER”
• 2x “webasto_HF”
• 1x “webasto_INTFLN1”
• 1x “webasto_INTFLN2”
• 1x "webasto_VENT_V"
• 1x “webasto_VENT_T”
• optional 1x “webasto_SHIM”
• 12x M5 brass inserts
• 12x M5x25mm machine screws
• webasto heater
• milwaukee packout
• other electronics

ASSEMBLY PROCESS

This build requires some DIY thinking, but it allows you to create this exactly to your liking. If you have a different box on hand these filled should be versatile enough to accommodate them. Here is a video that demonstrates jut how versatile this build can be

Some of the parts require metal inserts, which are used to create strong and reusable connections between parts. I used these high quality inserts sold by CNC kitchen. 

The primary components of this build include the coupler, the hose fitting and the internal flange that fastens it all together. The cross section of this assembly can be seen here →

To install this assembly, cut out a 75mm diameter hole in the front and back of the heater and insert the coupler from the outside. The internal flange secures it by 4 M5 screws for the outside. 

The Milwaukee packout I used has a slight bevel one on interior of the wall, which requires a slight different part, which is why I included “webasto_INTFLN1” as the alternative. See the picture in the model pictures. If the box you use to make it does not require this, please us “webasto_INTLF2”. 

The vent and vent template files are for the auxiliary air intake, which can be mounted anywhere on the box. The vent requires 4 M5 inserts. 

The shim is used to offset the exhaust pipe, to make room for a connection inside, and is only needed if you build it like mine.