How to Assemble a HHO Generator and Why It Works

How an HHO generator works and helps you save gas

An HHO or Brown gas generator is an interesting and often misunderstood technology.
The Brown gas generator uses electrolysis to split water (H2O) into it´s base molecules, 2 hydrogen and 1 oxygen molecule.
This is why it is often referred to as an HHO gas generator.The HHO in itself is not an alternative to gasoline but a additive
to boost the efficiency of the engine. Gasoline engines are unfortunately not burning gasoline to its full potential. See http://en.wikipedia.org/wiki/Engine_efficiency
The average gasoline engine in a car is about 18% to 20% efficient. That leaves a lot of room for improvement and Brown gas is one good way of improving the efficiency. The reason for this is simple, the hydrogen is highly flammable much more so than gasoline so when your engine ignites the hydrogen the explosion ignites the gasoline with much better results (cleaner, less waste and fewer emissions) than it would otherwise have done.

Some basics the burn speed of hydrogen is 0.098 to 0.197 ft/min (3 to 6 cm/min) compared
gasoline´s 0.00656 to 0.0295 ft/min (0.2 to 0.9 cm/min).

The hydrogen explosion is so fast that it fills the combustion cylinder at least 3 times faster then the gasoline explosion and subsequent ignites the gasoline from all directions  (it is like putting flue on a fire), instead of just a spark in one end of the combustion cylinder, and we would like to do that because the gasoline only has a short time in the combustion cylinder and if its not fully burnt in that short amount of time then it just goes out the exhaust and is lost.It is also preferable to ignite all of the gasoline when it is under maximum compression in combustion cylinder to get the maximum amount of energy out of it (this is a small time window),whonce the piston starts going down the energy transfer from the explosion to the engine becomes less efficient.

The hydrogen´s higher burn temperature and explosive force is such that it cleans the soot that collects in the engine (it is like having the engine consistent maintains) and with a cleaner engine you get better mileage and fewer oil changes .

Step 1: Tools and Main Components

Tools:

Screwdriver
Glue gun
Drill and bits
Metal saw
Soldering iron
wire crimp
wire cutters

Components:

HHO Generator
Pulse width modulator (PWM)
Electronic Fuel Injection Enhancer (EFIE)
Electric wires
Hose
Air connector
On/Off switch
Straps
Cable connectors
One way air valve
Piece of sheet metal
Peace of rubber
Glue

Step 2: The Brown Generator

I modified the Brown generator I bought on ebay by adding connections to the places and replacing the spacers with smaller ones to increase the surface area.
You will have to buy bottled water because tap water can have  metal in it that will rust the plates.
You will also have to ad an electrolyte to the water  to speed up the electrolysis.
The highest production of  hydrogen occurs with the plate polarity alternate as in +-+-+.( It also consumes the most amount of electricity)

Step 3: Pulse Width Modulator

Is an important tool to control the electrolysis. A simple generator can be built without PWM but that is like having an engine with only the possibility of full throttle or no throttle at all. The pulse width modulator is necessary for a controlled electrolysis. The specific frequency and power for the most efficient electrolysis wares form generator to generator.
You will have to fine tune the PWM your self but that is simple. You just fine tune the frequency first, by tuning the frequency up until the bubbles from the electrolysis plates start decreasing after you hit maximum bubbles and then go back to the best setting (producing the most
amount of bubbles) and then do the same for the power setting. It is best to get a powerful PWM at least 35 Amps preferably more.

I use a 50 Amp PWM and a LCD Display from canakit. http://www.canakit.com/50a-dc-pwm-motor-speed-controller.html

Step 4: EFIE

EFIE (Electronic Fuel Injection Enhancer)

The EFIE is intercepting signals from the oxygen sensor to the computer and fools the computer by giving it false exhaust readings from the Oxygen sensor.This is necessary because the computer is set up for a regular burn of fuel and compensates for the more efficient and cleaner burn by dumping more gasoline into the engine (until it gets the reading it expects) which ruins your fuel savings.
Gasoline burns better (cleaner less waste) with HHO gas because the increase burn temperature .

You can buy a EFIE on the internet or if you have the skills you can build one.

Step 5: Installation

I made a hole for the wires from the PWM to the Brown generator along side the existing electric cables,
the I put a peace of metal (with rubber on one side) around the Brown generator and screwed it to the frame of the car.
I drilled a hole in the air intake behind the air filter and inserted the air connector. I then put one way air valve on the hose
and connected the Brown generator to the engine.

Then I lengthen the cables of the PWM, thunk the variable resistors out and attached them til long wires, I also mad an manual on-off
switch  extension. I then used the glue gun to glue the PWM  to the top of the small glove box under my steering while,connected the wires slid the glove box into place  and then glued the variable resistors and the LCD Display in the small hatch where the fuses are.
It is all easily accessible bot not visible.