DIY Incubator Project #2

I spent some more time on the incubator project tonight.  First step was to rip out all the components that made it a functional freezer, at least those that were able to be removed without  me having to cause any damage to the basic properties of insulation that make a unit like this perfect to convert into an incubator.

Next it was time to give the freezer a good once over using bleach to clean it.  I paid particular attention to the door seals.  As with most if not all older fridges and freezers there was some mould built up in the seals, so a good going over was in order.  A quick hose down inside and out and it was sparkling....well almost.  I am a bloke after all.

Next step was to drill a hole from the outside at the back of the unit through to the inside to run both heat cord and thermostat probe.  You can see in the first picture that it went pretty well.  I passed all but the last few centimetres of the heat cord through, leaving only enough to plug it in when the time comes.

Then it was time to carefully work the probe cord through the same opening.  I used a 10mm drill bit with a view to fitting both cords through the same hole and then sealing it back up.  It was a tight fit and a bit fiddly to get them both through, but, I got there.

Not knowing how these sorts of things are constructed, it was interesting for me to see that there are three layers to the freezer.  There was the outer case, an middle insulating layer that looked like a form of polystyrene to me.  Finally there was an inner shell which looks to be a single piece of metal.  The outside was the toughest layer and it took a little careful work with the drill to get through.  The other two layers found the drill bit cutting through very easily.

Once I had the cords through the new hole it was time to start working on securing the heat cord appropriately.  For this, I used the 10mm cable clips I purchased earlier this week.  I actually found this task to be more difficult that I expected.  I spent the best part of half an hour trying to get the first pin hammered into the inside casing of the freezer with absolutely no success.  I eventually grabbed the smallest drill bit that I had on hand (1.5mm) and drilled some starter/pilot holes for the nails that fasten the clips in place.  It was then that I was able to get the nails driven home.  Even then it was more challenging than you would think.  Working in a confined space and trying to swing a hammer on obscure angles whilst trying to avoid fingers the size of mine at the same time is the reason I describe the process as challenging.  I tried a 2mm drill bit as well at the start, however, it was just that fraction too big for comfort.  This did mean that it was still an effort to get the nails in, but, better that than have them  not secure properly.  For me, making the initial holes would be the best tip I would pass on to anyone attempting the same thing.  As I said, it took me half and hour to get the fist clip secured.  The rest took me the best part of an hour once I got going.  I'd still be there now if it weren't for the holes.  No doubt cursing the name of anyone daring to come near.

This second image shows the results of my efforts.  You can also see the black thermostat probe in the middle of the top shelf.  I'm not entirely sure where I will fasten it in the end, but, for now, this stage of the project is complete.  I am pretty pleased with the results thus far.