I have been toying with alcohol stoves for many years now. For the most part I have stuck the designed of others. While the designs of others have influenced this one greatly, I am calling this my own.
It is a pressurized stove that does not need a pot stand. It has a large fuel capacity for a long burn time but can be adjusted by simply using less full. It is more durable than most stoves if its type.
It is heavier and larger than a lot of alcohol stove designs.
This is a tutorial on making one with items I had on hand, not with the best tools for the job. This is just to help show the ease in building.
I selected the aluminum bottle from a venom energy drink. Any aluminum bottle should work with this design, but I prefer venom. These have thicker walls than any beverage container that I have found. This make for a heavier stove than others out there, but it is much more durable. These bottles also work great as fuel containers. I chose not to remove the paint. I kinda like the way it looks with it, but simply sand it off if you wish.
Step 1: Select Bottle.
Just about any aluminum or stainless steel bottle can be used. I have selelected a Venom energy drink bottle because aluminum is easier to work with, free, and has thicker walls than any other beverage bottle.
Step 2: Remove Plastic Ring
The first thing is to get rid of the plastic ring around the neck. A Dremel make quick work of this, but working without one, this is the hardest part. If you want a smaller stove, you can cut the neck off at the bottom of the plastic ring.
Step 3: Cut Bottle in Half
Cut the bottle in half with the top part a little longer.
Step 4: Cut Flow Ports
Cut flow ports to allow the fuel to pass from the fill chamber to the pressure chamber.
Step 5: Press Top Into Bottom
Invert the top and press into the bottom. Being that it does have thicker walls, it is a little harder, but there is almost not risk of splitting out the side. Using a board will help give you more control and protect yourself. Press till top is seated to the bottom.
Step 6: Trim
You cannot see it in the photos, but you will be able to see and feel where the shoulder of the top and pressed out on the bottom. Move up about 1/4 inch and mark. Use tape or paper to mark a level line around the bottle at this point and trim to it as flat as possible. A saw will work, but scissors are easier to work with. The trauma shears I used made easy work of this. I then used the file from my leatherman to smooth and flatten the rim.
Step 7: Mark Jets and Drill
Wrap a piece of paper around the stove and mark the diameter. Decide the spacing you what for you jets and mark. Reapply the paper and tape in place so the jets will about 1/4 inch below the shoulder mark. I had a EKG strip handy and it worked great as a template. I place my jets at a 1 cm interval.
I want my jets small. I did not have any drills with me, but I did have a 24 gauge needle. The 24 gauge has a diameter of about 0.02 inch so that is about the size of the jets. If drilling, I recommend a 1/32 inc bit. drill through the outer wall only
The stove is now ready to use
Step 8: Testing
Burn time can be adjusted with the volume of fuel used. Maximum capability is 5 oz. That is more than most alcohol stoves, but gives a good deal of versatility.
For this test I filled stove with 5 oz of denatured alcohol, and 2 cups of water in the pot. ethanol (denatured alcohol) and methanol (HEET). avoid rubbing alcohol, it does not burn well. Do not used any oil based fuels and never used gasoline .
If you over fill, as the stove heats and primes and pressurizes, alcohol will sputter from the jets. This is not a big problem, but it waste fuel and prolongs time till stove can be used.
This is a self priming stove. All you have to do is light the center reservoir. As it heats the alcohol vaporized and pressurizes the outside chamber. The jest will light of the flame from the center. it will take a few moments for the flames from the jet to stabilize then you can place your pot on top. no post stand needed. I tend to prime externally lighting the center, letting it burn for one minute, then lighting the jets
>2 minutes for priming
5 min 45 seconds for rolling boil
total burn time 30 minutes.