If your control box has a brown crackle finish
with a lift-up lid and resembles a Kennedy tool box, you have a BX
type unit. If it is orange, aluminum, with no lid, it is a newer
BX Unit Upgrade instructions:
1. Creating a bottom
- Remove main air ball valve.
- Remove the 4 or 6 male quick disconnects from the opposite side. If
they are apparently frozen in place, use a small propane torch to heat them
(this unlocks the anaerobic sealant freezing them in), then remove the QDs.
- Open the lid and remove the 4 screws holding the anodized gauge plate in
- Tilt and nurse out the plate with the regulators, manifold and gauges still
- Look inside the empty box, noting where the wheel mounting screws penetrate
- Remove the wheels as they will interfere with the jigsaw.
- Layout the large hole you will jigsaw out of the bottom. Retain at
least .75" on each long side and at least .25" at the ends before
the swivel wheel mounts. (See picture) Round off the corner cuts, say
a 1" radius. This will give you plenty of working space if you
need to access the regulators.
- Cut out the BN unit bottom.
- Using a de-burring tool or a file, smooth the cut edges.
- Layout an overlapping cover plate, material of your choice. We use
.125" thick aluminum plate.
- Layout four corner screw attach points. Hold the overlapping cover
plate in position and drill pilot holes. We use AVK rivnut inserts,
AK series with female 1/4-20 threads, at each corner. Pilot hole size
for these AVK inserts is 25/64ths". We attach the new cover plate
with socket head 1/4-20 x 3/4" bolts; use what you're comfortable with;
it's a low stress item.
- Look into the steel manifold and see if it's cruddy internally or rusty.
If so, this is a good time to disassemble it and take the manifold to your
local automotive machine shop where they can boil it out overnight like a
carboned-up cylinder head in hot sodium hydroxide. When you get it back,
pour a few ounces of boiled linseed oil into it,
slosh it around to thoroughly wet all areas inside. You might want to put
masking tape over the openings while you do this. Shake and drain it
well; then dry the interior with a heat gun or hair dryer. You could
spray an outside coat of metal paint on the manifold while you're at it.
- Re-assemble the unit.
2. Adding an Aero-Jack
- Most BN units have a 1-1/2" FPT fitting in the manifold. Some
are 1-1/4". Check yours. Then get a hydraulic
grade hex nipple that is sized to fit your BN unit. These
are a phosphate coat, gold color.
- Drill a 13/64ths pilot tap in one flat of the hex. Then use a 1/8th
NPT tap to thread this hole.
- Remove the ball valve and nipple that came with the BN unit. Screw
the new hex nipple into the manifold. Position it horizontally on the
left side (see pic). Screw in an automotive type
female QD with 1/8th NPT male base and sealant into the newly created 1/8th
NPT female aperture you've created. Screw on the ball valve and male
QD for the main air inlet.
- re-attach the 4 or 6 male outlet quick disconnects.
- Pressurize the BN unit and check for leaks.
- AeroGo inflatable jacks, capacities ranging from 10 tons to 140 tons, and
the whole world of air tools can now be connected to your system. Enjoy.