Step 3: Exhaust gasket and prepping the sheet metal

Here are some close up pictures of the exhaust gasket. Garages that do a lot of exhaust work might have some spares or know how to get one. Take the Coke bottle with you to make sure it fits.
The gasket measurements are:
inside diameter- 2 9/16"
outside diameter- 3 1/16"
height- 17/32"
ring width- 7/32"

(Not pictured) With the Sharpie trace the outside diameter of the PVC onto the sheet metal. Cut out the circle with a jig saw. File and shape the circle on a grinding wheel or with a Dremel tool. The diameter should be 3 1/2".

Center the exhaust gasket on the sheet metal. Holding a mechanical pencil straight up and down, trace the inside of the gasket. There should be a small gap between the line and the gasket. Cut out the center of the sheet metal. I drilled some holes around the center then cut it out with a cutting wheel on the Dremel. File and smooth the edges with the Dremel. The inside diameter should be approximately 2 3/16".
Do you still make these for people? I want to build one but the cost of the tools I would need is to much right now
So I'm making this and I'm really excited to get started. However, how important is the acrylic glass? It's a bit pricey and I don't have the ability to cut it. Is there an alternative I can use?
<p>Thanks, I had great fun making this, plus the thrill of pluging something electronic I had made into a socket :P</p>
<p>What diameter does the 3&quot; PVC have?</p>
<p>3 inches diameter. 3&quot; actually means 3 inch, not a code for special PVC if that's what you though initially.</p>
How important is the thickness of the glass? I got one thats .093 thick and I want to get started
<p>Is there an overall cost to this or did i just miss it.</p>
It took us a while, but my dad and I finally finished this project. All we have left is to put the labels on the bottle and base. <br>I found the gasket at O'Riellys, I gave them the part number that a previous commenter provided for autozone.
correction: advanced auto parts
wow this really cool!! looking forward to making it!
Hello, I wanted to ask, does the power jack have to necessarily be a size K? (kinda new to this whole &quot;circuits&quot; stuff) Thanks!
<p>Late reply is late, but no. As long as it's rated for 9 volts, you'll be fine!</p>
I work for advance auto parts the gasket you need is felpro 60986 its $2.49 it fits a Chevy truck v8 around the years 1968-1991 its also called a exhaust flange gasket hope this helps everyone
<p>very very cool, love it.</p>
I saw ur post on reddit o_o
Hi, i am from England and would like to buy one, please contact me with the price or something. BTW I love the workmanship involved you have an amazing skill ;]
to me that gasket looks familiar. I used to weld pipes. at that work place, we had to bevel the ends of the pipes to prep them for welding. sometimes the pipes had to be cut really short, like 3/4 of an inch long, and still bevel the ends of the pipe and they would look just like that gasket. many times we would cut it wrong and not know till it was beveled. we threw away many pieces that looked almost exactly like this part. with a lathe i could easily make this part. with a hand grinder i could manage to make the part with a lot of patience. but who says it has to be metal. paint can make anything look like metal. so there should be a lot of options with other materials too, right?
Hi there <br> <br>Trying to follow the schematic for the LEDs but I don't actually have any electronics experience. It looks like your LEDs were wired in parallel, and wired to a 9V battery - so roughly how long would your lamp last when turned on? <br> <br>Also given the different forward voltages in a blue/UV and red LED, are the red LEDs not much dimmer as a result of being in the same circuit? Or have I misunderstood? <br> <br>Cheers for any help :)
Yes they are in parallel but I used a 300 milliamp power supply that plugs into the wall instead of a battery. I did this for stability and so I wouldn't have to change batteries. <br> <br>You could easily use a battery instead of a power supply though. In fact I added a 9 volt battery to my circuit so I could use either the power supply or the battery. I did the math and figure the battery should last about 10 or 11 hours. <br> <br>Here's the thing with the LEDs. I used LEDs from Christmas lights. They are all the same voltages. I think they are white LEDs in red and blue colored acrylic plastic. I don't know their exact voltages but 3 volts lights them up nicely so they worked perfect for 9 volts. <br> <br>That being said, I'm not happy with using those LEDs. I want to remake the circuit using real red and blue LEDs. With the higher voltages of the blue LEDs I'll need to use a 12 volt power supply and use resistors for all three LED sets. When I get this done I'll update the schematics and add some pictures.
love the design. I have the base already completed and working on the bottle. I'm having trouble finding the right kind of paint. what was the brand you used and where did you get it? thanks for the help.
The exact paint I used is &quot;Dick Blick&quot; &quot;Blickrylic&quot; I got it from my high school art class about 20 years ago. I couldn't find it in the craft stores I've been too but its available here. <br> <br>http://www.dickblick.com/products/blickrylic-student-acrylics/
Hi, what kind of glue you used to glue the label to the bottle? I have normal paper glue (probably doesn't work), fast-drying glue (which seems to dissolve the ink), hot glue and wood glue. Do I need to get some specific glue or will some of these do?
And another thing, if I use the wood glue (It's called Eri-Keeper if you know), should I leave the original Coca-cola label on? The Nuka-Cola label would probably stick better to that than to the glass bottle.
I tried normal paper glue first and it didn't work at all. I ended up using Gorilla glue. which will stick to the glass no problem but I find its messy and hard to work with. Not sure about the wood glue. I'm going to try using rubber cement next and see how that works. <br> <br>Leaving the Coke label on under the Quantum label might give better adhesion too. Maybe sand it lightly. I'll have to experiment with this.
I got it working already, just left the Coke label there, no sanding and just normal paper glue! Works like a charm :) <br>Thanks! <br> <br>Also, I used the USB's 5 volt power to light the two LED's I have (with 68 ohm resistors, as I calculated) but it first flickers a couple of times with a bright light, then it just dims to way too little light. Where's the problem? The LED's forward voltage is 3,7 volts and forward current is 20mA.
(Apparently I can't delete my own comments..) <br>I solved that one too, it happens because when you connect the USB to your computer, it sends signals that determine whether there is a device connected to the USB. When it receives no data from it, it stops sending the signals. You can apparently fix it by simply taking an old Nokia USB charger (you know, with the round head). It seems to have a small circuit that tells the computer to send +5V to it. <br> <br>Thanks anyway! :)
I got it working already, just left the Coke label there, no sanding and just normal paper glue! Works like a charm :) <br>Thanks!
If you're selling, i'm buying.. how much ?
I have another request from someone to buy one. I need to see if I can find some more exhaust gaskets. If I can I'll make a couple to sell. Not sure on the price yet. I'll get back to you on that.
Excellent ! keep me posted, should be possible to find some through junkyards or from a professional welder i bet...
I was able to order the exhaust donuts from Car Quest. I started building more of these But I've been petty busy and haven't been able to work on it much. I have some time now and will be working on these again. I need to get some more parts and rework the LED circuit. I'm not happy with it how it is and want to improve it. I'll keep you posted.
Found one on Amazon.com for about $6 <br> <br>http://www.amazon.com/gp/product/B000CQV0SI/ref=ox_sc_act_title_1?ie=UTF8&amp;smid=ATVPDKIKX0DER
This is a terrific build! I love the lighting system you designed. It looks so excellent when it's lit up. <br> <br>I'm going to start keeping my eyes out for an exhaust flange now. Also, it gives me an excuse to go enjoy the taco truck, to get my Mexican Coke bottle. :) <br> <br>Instead of re-gluing the cap, if you know anyone who's a homebrewer, they can cap the bottle with a brand new cap for you. <br>I picked up a capping machine at a homebrew shop for about $15, and a big sack of caps for about $6. (I was holding this big sack of bottle caps and thinking &quot;I'm rich!&quot;)
thank you and thanks for the tip on the capping machine. I'm gonna have to get one of those.
Did you decide to make some and sell them cause if you did i would love to buy one off of you. These look really sweet. <br> <br>
Sorry for the late reply, I've been real busy. Yes I am making these for people that request them. I have a bunch of them started but I need to get some more parts and rework the LED circuit. (I'm not happy with it as it is) I'll keep you updated.
If you go to an auto store looking for the exhaust gasket be aware it is probably called a donut instead. Still, a part number helps a lot! Not all exhaust donuts are the same size. <br>
This is an interesting build. I may try this soon and maybe add an alarm clock to it.<br> <br> Also, I was looking for the exhaust gasket you used online and I think I managed to find it. I believe the part is called a FX318 Steel Donut Gasket.<br> There seem to be a couple makers with parts numbers including: Rol #EG24109 and Maremont #521006.<br> <br> It has the 2-17/32&quot; inner diameter you mentioned above as well as the same shape on the top and bottom. I've managed found it on a few different sites. The part is still a little hard to find, but hopefully this will make it a little easier.<br> <br> Thanks for the great guide. This should definitely keep me busy for a while.
Awesome! Thanks for the info on the gasket. It should make things easier for anyone else that wants to build this. The alarm clock is a great idea. I'd love to see pictures of yours when your done.
Dude! Brilliant!!!!
What fun! How long does it last? Congratulations on being &quot;Featured.&quot;
Thank You. I made one about a year ago and over time the paint settled to the bottom of the bottle. The liquid becomes clearer and doesn't glow as brightly. All you have to do is shake it up a little and that mixes everything up. It'll look as good as new.
Good to know! Thanks!
beautiful! <br>
Looks amazing!
Love it!
Well done!
That's fantastic! I always loved collecting these in the game. :D
Awesome! Great attention to detail with the pop cap!

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