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This project is part of a series of instructables from ALL Power Labs showing how to create a Honda Accord that runs on wood gas.
This project is entered in the Craftsman contest, if you like this project I hope you will consider voting for it. Just click the "Honda Accord" link above to go to the main project, then click the "Vote Now" button. Thanks!! (note from after--- we won! thank you to all who voted for us. the shop is now much more full of tools thanks to sears)
This portion of the project shows fabrication instructions for the Open Source Gasifier Experimenter's Kit (GEK) from ALL Power Labs.
Note: The following fabrication instructions assume you already have cut out or otherwise acquired the necessary sheetmetal vessel tubes, flanges, plumbing parts and other accessories. If you have yet to do this, return to the main project Instructable and finish your prep work before continuing from here.
The GEK gasifier system consists of the following seven components. We will be building each of these components separately, the returning to the main project Instructable for final assembly and preparation to run.
Gas making:
1. Gas cowling and ash grate
2. Downdraft reactor
3. Fuel hopper
Particulate clean-up:
4. Cyclone
5. Packed bed filter
Gas combustion:
6. Centrifugal vac/blower
7. Swirl burner
CAD drawings for all the sheet metal parts and assembled vessels for how to build a GEK wood gasifer are in the main project Instructable, as well as on the download page of the main GEK site http://www.gekgasifier.com
This project is entered in the Craftsman contest, if you like this project I hope you will consider voting for it. Just click the "Honda Accord" link above to go to the main project, then click the "Vote Now" button. Thanks!! (note from after--- we won! thank you to all who voted for us. the shop is now much more full of tools thanks to sears)
This portion of the project shows fabrication instructions for the Open Source Gasifier Experimenter's Kit (GEK) from ALL Power Labs.
Note: The following fabrication instructions assume you already have cut out or otherwise acquired the necessary sheetmetal vessel tubes, flanges, plumbing parts and other accessories. If you have yet to do this, return to the main project Instructable and finish your prep work before continuing from here.
The GEK gasifier system consists of the following seven components. We will be building each of these components separately, the returning to the main project Instructable for final assembly and preparation to run.
Gas making:
1. Gas cowling and ash grate
2. Downdraft reactor
3. Fuel hopper
Particulate clean-up:
4. Cyclone
5. Packed bed filter
Gas combustion:
6. Centrifugal vac/blower
7. Swirl burner
CAD drawings for all the sheet metal parts and assembled vessels for how to build a GEK wood gasifer are in the main project Instructable, as well as on the download page of the main GEK site http://www.gekgasifier.com
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Signing UpStep 1Fabrication methods and standards
Fabrication Method and Standards
All GEK vessels are fabricated using the same three basic part types: vessel tubes, flange rings, and end plates. Flange rings and end plates are welded on the ends of the cylindrical vessel tubes. Flange rings are usually at the top of a vessel tube, and fit around the outside of the tube. End Plates are usually at the bottom of a vessel tube, and fit inside the tube.
In all vessels, the circular plates/rings function as the jigs to pull the vessel tubes to perfectly round for welding. Tabs and slots on all vessels simularly index the pieces together and ensure an accurate finished product. This system of self-jigging is central to the ease of building the GEK.
While following the step-by-step instructions that follow, be sure to remember these other common standards across the kit.
- All flange rings and end plates should be oriented such that the slag side is down. (note: Oct GEK run needs the reactor bottom plate flipped so slag side up. we made a mistake on this one)
- All vessel tubes are rolled such that the slag side is facing inward
- All vessel tube seams should be in the rear center of the vessel
- All large vessel tubes will have approximately 3/8" overlap at the seam joint. This makes welding much easier than welding sheet edge to edge. The smaller vessels (cyclone and swirl burner) will have 1/4" overlap at the seam
- Tabs and slots will give you the correct positioning. But do be careful to center the first tab and slot so the others will come out correct. See notes in below text for details.
- When welding flange rings and end plates, start with short stitches around the circle. Do not do one long continuous weld or you will warp the flange.
Once you've built all the components listed below, you can proceed on to Assembly Instructions for how to put them all together into a functioning unit.
All GEK vessels are fabricated using the same three basic part types: vessel tubes, flange rings, and end plates. Flange rings and end plates are welded on the ends of the cylindrical vessel tubes. Flange rings are usually at the top of a vessel tube, and fit around the outside of the tube. End Plates are usually at the bottom of a vessel tube, and fit inside the tube.
In all vessels, the circular plates/rings function as the jigs to pull the vessel tubes to perfectly round for welding. Tabs and slots on all vessels simularly index the pieces together and ensure an accurate finished product. This system of self-jigging is central to the ease of building the GEK.
While following the step-by-step instructions that follow, be sure to remember these other common standards across the kit.
- All flange rings and end plates should be oriented such that the slag side is down. (note: Oct GEK run needs the reactor bottom plate flipped so slag side up. we made a mistake on this one)
- All vessel tubes are rolled such that the slag side is facing inward
- All vessel tube seams should be in the rear center of the vessel
- All large vessel tubes will have approximately 3/8" overlap at the seam joint. This makes welding much easier than welding sheet edge to edge. The smaller vessels (cyclone and swirl burner) will have 1/4" overlap at the seam
- Tabs and slots will give you the correct positioning. But do be careful to center the first tab and slot so the others will come out correct. See notes in below text for details.
- When welding flange rings and end plates, start with short stitches around the circle. Do not do one long continuous weld or you will warp the flange.
Once you've built all the components listed below, you can proceed on to Assembly Instructions for how to put them all together into a functioning unit.
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Hi Jim found this page by checking my referral log on my web site......
Burn Baby Burn!!
Jonathan
www.woodgas.net