Step 2: Getting Metal For The Generator Plates
I used 20 gauge stainless steel, and with the help of their hydraulic punch, cut precise holes in the tops and bottoms of the plates. When finished, I had 12 plates measuring 3" x 6", 4 plates at 1-1/2" x 6", and three 1" connector bands that were 6", 4-1/2", and 3 1/4". A belt sander was used for smoothing down the jagged edges around the hole.
Step 3: Increasing The Plates Surface Area
Step 4: Configuring The Plate Assembly
The generator plates are assembled in the order of plate, plastic washers, plate, stainless steel jam nuts until 8 plates have been connected.
To see a step-by-step of the generator plate assembly, watch that specific portion of the video here.
When the plates are assembled, a 4" ABS clean out plug is attached at the top with some stainless steel bolts.
Step 5: Making The Generator Body
A water bubbler is made in a similar fashion out of 2" clear acrylic tubing, but needs a way to clip onto the side.
Step 6: Making Clips For The Bubbler
To make these clips, I cut 3/4" off the 2" tubing I used to make the bubbler, then cut the top 1/3" off to form a claw. These were then cemented to acrylic rods, and attached to the side of the generator body.
Step 7: Adding a Check Valve
Step 8: Making The Electrolyte
I stirred the KOH flakes into the water, then used a coffee filter to strain the solution into the generator casing (after it had been cleaned thoroughly).
Note: Potassium Hydroxide is caustic and can burn the skin. Avoid direct contact!
Step 9: Finishing Touches
I tested it out with a 12 volt car battery and some jumper cables. The gas formed is collected it in a small water bottle, and ignited with a flame.
On 12 volts, this produces about 1.5 LPM. I also hooked it to 2 car batteries in series, and on this higher 24 voltage, the system produced over 5 LPM and filled up a gallon milk jug in 38 seconds!
Note: Higher voltages allow more current to flow through the system, and it heats up quickly over time. If allowed to continue, there is a risk the plastic casing will melt from prolonged exposure to high temperatures.
Step 10: How Powerful Is The Gas?
To see some experiments where the gas was ignited, and some useful features of the generator, check out the video.
If you liked this project, perhaps you'll like some of my others. Check them out at www.thekingofrandom.com