My plan was to make a better furnace for melting aluminium but debating this with my wife she made a good point of how many time I would use the furnace Vs how many time we will sit out on a cold afternoon in the garden with a worm wooden stove.
So the wooden stove was the winner.
In this instructable I will show you how I made it all from recycled scraps at minimum cost. The total I think was 20 bucks. The only spend was on grinder discs, welding electrods and a special stove paint although you can save on that to if you don't wish to paint it.
Yesterday we used the stove first time and we sat beside it for over 3 hours and it kept us warm. The only thing I will have to change is to a bigger flue pipe but other then that its a super success.
Safety disclaimer : When using electric tools: welding, cutting, grinding always use ears and eye protection. Keep body parts away from sharp blades and always use full body protection gear.
If you don't know what you are doing take it to a professional. Misuse of pressured gas cylinders can cause injury and even fatalities.
This is not an instruction or a guide how to do it, I am sharing with you how I used a gas cylinder based on my own experience and knowledge.
Anyone who attempts this he/she will do it on their own risk, I will not be liable for any injuries in anyway.
Step 1: Gas Cylinder From the Sea
I was walking on the beach and was suprised to find a gas cylinder washed ashore wedged between the wave breaker boulders, it was strange as I was just thinking that day that it would be cool to use a cylinder for a new furnace and there it was.
I was suprised even more when I found another one not much further away in the sand.
Then I was thinking what sort of people litter the ocean like that. I will just holdon to my naive tought that it accidently fell from a fishing boat ..yeah right. Then again yesterday while I was cycling I saw another 2 gas cylinders thrown in the woods and 3 more thrown at the port. I really dont get this.
Anyway back to our instructable. After emptying the gas cylinder for a few days (It was empty when I found it) but just to be on the safe side.
After releasing the gas cylinder pressure I drilled a hole and filled it with water and another small hole for letting air out when emptying the water. I left it for a few weeks changing the water every few days.
While cutting the stove future door I placed the gas cylinder on its side full with water and I hosed it every few minutes between the cuttings too cool it down.
After cutting the door out I cut the cylinder nozzle and the handle off (free handle for another project). A bit of grinding and we are ready to start.
I found this is video on You Tube and it is shocking too see the stupidity of some pepole and how they risk their lives.
Look at these lads doing everything wrong, first it looks like the gas bottle is not fully emptyed and they're not wearing any protective gear.
The cutter guy is holding the gas cylinder under his feet rolling it while cutting.
The best part: look at the arrogance at the end of the clip when the main charactrer need to warm his cold hands.
This video clip shows how NOT to do it:
Step 2: Making the Stove Door
I got the straps of metal from un-used metal head board.
I cut the straps with a hack saw to fit the stove door size and since I don't have a bending machine I used the door as my template and my muscles to bend it over into it shape.
Next sanding all that rust off, I wonder how long it was driffting in the sea and where it came from??
I found my welding magnets handy for holding the metal parts in place.
For welding I used my Grip Locking Pliers starting from the top welding from the door inside part.
Unfortunately I dont have a TIG Welder so I was using my primative but reliable ARC welder and My limited welding skills.
I started with a few tack welds and placed the door in its place to check the fitting.
Weld the top thenthe bottom and last the sides.
After all frame straps are tacked, welded, check the fitting again and if you are satisfied give it some more extra welding.
Step 3: Door Handle and Hinges.
I made the door handle from a big nut rounding it on the grinder. Welded another small nut to it so it could be screwed onto the threaded rod. Another small nut over the threaded rod is to secure the handle into any angle desired.
You can drill a hole into the big nut witha press drill but its not really necessary with the small nut welded to it.
Drill a hole in the door no more then the threaded rod size. Weld the nut into the inner side of the door and screw the threaded rod into it.
I used scrap metal bits from the same head board frame, cutting the straps witha hack saw 45 degrees at the edges then I drilled holes using the drill press for the hinge bolt.
After drilling I cleaned them stripping all paint with my small grinder.
Connect all hinges together, tighten the nuts and release them after welding is finished, use magnet to hold hingein the right place for welding.
Make a final check that the door and hinges are in good location then tack weld open the door to check that everything is as it should be. Close the door and add more welding to the hinges.
Step 4: Door Lock
For the doors inner lock I used a bit of scrap metal from a garden metal box.
Cut to size with angle grinder and place between the two nuts tightening them with 2 spanners after adjusting the door handle in the right location.
Step 5: Stove Vent Holes
I drilled Vent holes at the bottom of the stove.
I cut off the base support of the gas cylinder with a grinder that way I could attach something more decorative and get rid of the gas cylinder look.
I used my old cast iron BBQ that was more of a decorative item in my garden for flower pots. After taking it apart it will serve as the new stove base.
Next cleaning the rust using my grinder with a metal brush disc. I did this in the open with a respirator because of all the rust coming off.....not healthy!!!!!!!
Lastly a bit of cosmetic welding: close the water and air holes I drilled and grinding them smooth.
Step 6: Stove Hot Plate
I really wanted a stove that will be functional in a few ways. One of them is a hot plate on the top of the stove to boil water for coffee / tea.
I didn't have a metal plate so one day I went for another walk down the beach with my baby and there it was in front of me in the sand. I pulled it out and got all excited it was the perfect size - about 5mm thick steel plate.
With all the rust on it I wondered how long it was in the sea. Maybe it was part of a ship hull that was cut off.
I started with a hammer taking the big chunks of rust off first and then brought the "heavy machinery" into action.
After finishing grinding the rust I marked the shape for the stove hot plate and cut it.
Mark plate center point and weld a bolt to it.
Attach washer and nut, fasten plate to place and check if the fitting is good.
Step 7: Vent Door.
I used an old work bench metal part for the vent door. I hammerd it flat and got rid of the small angle on it. Then I cut it into 2 parts and tack welded them to each other to acheive a thicker door. Check vent door fitting.
Then I made another small hinge the same as the one for the main stove door.
I used the same method, securing the hinge to the right place and then welded it.
The door handle I made from more scrap I had, cut it to size and grind a lock shape.
I attached a threaded rod as a handle and secured it with another nut.
Step 8: Securing Base and Painting.
To secure the base I drilled a hole into the stove base and used a long bolt connected to the metal strap pulling both parts together when tightening the nut.
The strap metal is made from an extra grinder key I had - drill a hole in the center of it .
After the base is attached cover all parts that you dont want to paint and spray it with a special stove paint. This will be the first coat of paint.
Do it in a well ventilated place and wear a respirator.
I felt that something was missing and I had that space on the front stove door so I attached my old house no' , I think it looks cool :-)
Step 9: Stove Flue Pipe
This step shows how I made the flue pipe but It will have to be replaced by a bigger diamater flue to handle all the smoke.
I used a box iron from the metal head board frame.
Drill holes in the gas cylindr or use a grinder for flue pipe whatever is easier.
Cut small part in 45 degreed and weld the longer part to it.
Step 10: Inner Grill (optional Step)
This step is optional.
The grill could be used to place timber on it and the ashes will fall down and you will have good air circulation or your second option you can light charcoals under the grill and place a pot on top for cooking.
I used masking tape to get the right locations for drilling the holes all around at the same height.
Drill a few holes around and attach long bolts to support the inner stove grill.
I had only a small grill so I added another layer with garden wire.
Step 11: Making Coffee and Aluminium Ingots.
The stove was great when we used it the other day in the garden, the only thing again is replacing the flue pipe to a bigger one.
I placed the stove on tiles just incase it will get too hot and burn our new deck.
I checked the temperature of the hot plate and inside the stove with a multimeter and I was amazed how hot it can get. The hot plate was hot enough to boil a pot of water and inside the stove was hot enough to melt aluminium.
So I got three in one - a furnace, a garden heater and a cooker stove...... :-)
One more thing I recommend: use stove gloves to avoid getting burned and to make some stove tools such as a fire poker, small shovel and clamps.
Why aluminium you ask , you are welcomed to check my Charcoal Furnace instrucable:
Hope you enjoyed my instructable :-)
Here are 2 short clips of the stove in action:
First clip Boiling water for coffee...
Second clip of a fresh aluminium ingot:
Step 12: Finally Found a Chimney
This step is 10 months later. I finally found a chimney pipe in a scrap pile. I removed the heating plate and attached the chimeny pipe to the top of the stove. It is PERFECT now.