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01 Background
The outdoor stereo system was built in Manalapan, New Jersey in 2014 using a recycled instant hot water heater as the enclosure. A desktop PSU powers a car stereo head unit inside the stainless steel shell. The project involved gutting and cleaning the heater, applying Plasti-dip insulation, installing a GFI outlet, building MDF shelves, wiring terminal blocks and speakers, and mounting a marine antenna.
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02 Photos
Build process from recycled hot water heater to finished outdoor stereo.
A look at the back of the newly purchased unit. Different type of high-quality RCA Cable ports for an amplifier as well as a Wiring Harness Clip. Antenna Plug visible in the bottom left. Heatsink in the middle.
Rear of the New Stereo Unit
An infrared remote, wiring harness, and other components that came with it.
Higher Resolution picture of the back of the Stereo.
Successfully powering it on for the first time using a Desktop Power Supply.
This is an Instant Hot Water Heater. This particular one seen on the right, was a replacement unit due to a recall. The old unit was experiencing corrosion due to water exposure which could pose a potential risk if a gas line or water line cracks within the unit.
Instant Hot Water Heater (Enclosure)
Here is the old unit that was previously destined for a garbage dump for recycling.
The unit comes with an existing Power Cord, I can definitely repurpose this to make a clean looking installation for powering the unit.
Repurposing the Existing Power Cord
Here are the internal components. The insulated cylinder has a coiled pipe running around it. Below it a burner would heat up the water as it travelled through the coil. This would flow out on the left side in the middle.
Internal Components of the Heater
All internal water heating elements were removed and put aside for recycling. There is visible corrosion on the bottom of the unit which should be addressed.
Internals Removed, Corrosion Visible
Corrosion on the Side and Bottom Pan
The left side of the unit (looking outwards) where the Power Cord is visible. The Exterior of the unit looks great!
Left Side with Power Cord
Front door was removed (using 6 screws). There was a control panel on the bottom which is why there is a hole there. I can repurpose this for something. Possibly an Infrared Receiver / Transmitter for the remote.
Front Door Removed
Time to address the corrosion now that the door is out of the way.
The top also had intake and exhaust PVC Connections which need to be patched. These were dimensioned for 3D printing brackets later. The other 2 are intake and output of water, which can be sealed with standard plumbing fittings.
PVC and Plumbing Connections on Top
The unit interior was sprayed with a few coats of Plasti-dip, which is removable, if ever need be. Plasti-dip is a sprayable plastic which waterproofs the seams and ensures insulation from any potential conductive surfaces.
Interior Coated with Plasti-Dip
A Fast-Action GFI (Circuit Breaker) was installed on the right side using existing holes. A 6-port Surge Protector was also installed on the bottom. There are rubber feet, so the unit will not experience pooling of water underneath. GFI would trip if ever exposed to water just in case.
GFI Breaker and Surge Protector Installed
Lights are on, on the Surge Protector - Power Success! 1st MDF Shelf is now in place on top of 3D Printed Right Angle Brackets (Also seen in Mendel90).
First MDF Shelf on 3D Printed Brackets
Second Shelf with 6" Spacer Blocks
Two Shelves and Bottom Compartment
This Unit may be brought in during the winter months, so to make connections easy to remove, yet modular, I'm using a Screw-post Terminal Block. Speakers can be added and disconnected easily.
Screw-Post Terminal Block for Speakers
Stereo successfully powered up within the Unit with the Existing Power Cord!
Waterproof Outdoor Speakers are wired into the Screw Terminal Block for Testing!
Using the existing wiring clips, I was able to clean up the wiring of the Desktop PSU - which looks very professional now. 12V and 5V Molex connectors are there if I want to add interior lighting or anything in the future as well.
Clean PSU Wiring with Molex Connectors
Testing the fit of using insulating plastic tubing for professional appearance. This is out of a convenient power on the left side which originally served the purpose as a drain.
Insulating Tubing for Side Power Output
Speaker wires run through the existing threaded drain connector and are hooked up to the screw terminal block. All pairs of wires are labelled for best acoustics.
Speaker Wires Through Drain Connector
Hooking up 3 Speakers to test Fading Feature. We can create different zones of audio in our backyard (Pool Side, Deck Side).
Testing 3 Speakers with Fading Feature
First time the unit has seen daylight! Everything going well so far.
Finally moved to its proper location. We have a small 2' x 2' Box in the Middle of our deck. This was coincidental but very convenient and fits very well there! Awesome!
Installed on the Deck
Marine Antenna Fitted on the side, 3D Printed Tops can be seen here. Unit doesn't look too obscure, Eternal doesn't shout Hot Water Heater, and it works very well!
Marine Antenna and 3D Printed Tops
Hinges were retrofitted onto the door so that it could be opened when access was needed. I kept the stickers on the interior to share with guests, I'm sure they'd love the project.
Hinged Door for Easy Access