Outdoor Wood Furnace Info

Outdoor Furnaces - Manufacturers with NON EPA-Certified Models Only => Home Made => Topic started by: jackel440 on September 23, 2010, 06:42:31 PM

Title: Gasification wood boiler build
Post by: jackel440 on September 23, 2010, 06:42:31 PM
Alright everyone my gasifcation boiler build is now starting.Today we sheared and bent a ton of metal,and then hauled it all home.Unloaded it all by hand as my skid loader is over at a woods I am helping my nieghbor log out.
Here is a quick run down of what I have planned.28" wide by 48" deep by33 5/8" tall fire box in a 36" wide 60" deep and 60 " tall water tank.
Approximate 400 gallons of water. >:D
I still have refractory brick to purchase yet.Plus my electronics and fan and damper actuater.
I hope to have this project done by the end of Oct depending on funding for the rest of it.
Pictures will follow as I progress. :)
Title: Re: Gasification wood boiler build
Post by: jackel440 on September 23, 2010, 06:50:20 PM
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on September 23, 2010, 06:51:10 PM
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Title: Re: Gasification wood boiler build
Post by: Larson88 on September 23, 2010, 07:08:50 PM
400 gal wow... i dont think you can have to much water! Cant wait to see more pics, good luck with the build
Title: Re: Gasification wood boiler build
Post by: MattyNH on September 23, 2010, 07:14:58 PM
Good luck!...Looking forward to the pics!
Title: Re: Gasification wood boiler build
Post by: jackel440 on September 23, 2010, 07:17:36 PM
I have been researching this for a long time ,and I believe the key to this whole deal is mass storage.I plan in the future to have atleast a 1 to 2 thousand gallons of super insulated water tanks.That way you can run the furnace full bore and make the heat and then shut it down and live off the stored hot water.
I have kind of put a kink in that plan with such capacity I will have.But I don't know how long it will be before I will get my storage made and installed.
I am still excited though :D
Title: Re: Gasification wood boiler build
Post by: Scott7m on September 23, 2010, 08:02:27 PM
What your doing is possible....  mass storage units are something used by gasification units that typically sit in a garage or basement.  they are really efficient but often require you to build a fire daily and store the hot water in a pressurized tank. 

If you get your 400 gallon tank working I cant imagine wanting 2000 gallons.  The 400 should be really impressive I would think.
Title: Re: Gasification wood boiler build
Post by: koutsman on September 23, 2010, 08:35:07 PM
I think 400 gal. will work out great for you. My legend boiler holds 500 gal. and that seems to be great , you can run out of wood and the water will keep heating for along time!!! I think gallonage is the key.
Title: Re: Gasification wood boiler build
Post by: willieG on September 23, 2010, 08:42:57 PM
i have been reading..if you heat a 2400 gal tank of water to 180 degrees and you could make it so you have no heat losses (impossable) you could heat an average 2000 square foot home for 3 days in average winter temps (i am thinking here maybe in the low 30's?)
 
lets play with the numbers..1 btu raises 1 pound of water 1 degree (thats a btu)  2400 gal is pretty close to 24000 pounds  so if my math is right we need to multiply 24000 pounds by about 130 (our water should allready be about 50 degrees) to get enough btu's to reach 180
that gets us to needing 3,120,000 btu to heat our water , and lets say our stove is 75 percent efficient. we now need 3.9 million btu for 3 days of mid winter heating. a cord of good dry hardwood has about 20 million useable btu in it. that gives us about 1/5th of a cord for our needed btu. So using that we need about 1 cord of wood for 15 days of midwinter heat or 1/5th of a cord for 3 days heat

any of this make sense??
Title: Re: Gasification wood boiler build
Post by: Scott7m on September 23, 2010, 10:40:20 PM
if willie's numbers are correct your wasting your time.. 

Title: Re: Gasification wood boiler build
Post by: willieG on September 24, 2010, 04:51:02 AM
you can work the numbers alittle different for where  you live

in ontairo canada the normal estimate is 100 million btu a season (this can change to a rapidly lower number with a new house now)
5 cord of good dry hardwood can produce this  but you must add some (depending on the efficiency of your stove)
this is a fairly accurate average) as my home is a century old farm house but i have added insulation and windows  and my home built stove is likely not much more than 50 or55 percent efficient and i do burn about 8 to 10 cords (depending on the winter) and when my leaky old underground pipes were good.
Title: Re: Gasification wood boiler build
Post by: willieG on September 24, 2010, 04:54:03 AM
personally i say ...build it

if it dont work, lower the storage..if it does work...GREAT, and if you don't build it, you will always wonder. If you do build it you will know.

And as a tinkerer myself..when you build something for yourself...it is not a waste of time but "research and development" LOL
Title: Re: Gasification wood boiler build
Post by: jackel440 on September 24, 2010, 09:37:29 AM
Willie
  I Completely agree with you about the research and development theory.I have a plan and I see it working.if it doesn't pan out I can reuse it or scrap it.
I also think I might be able to go longer than the projected 3 days with mass storage,as I live in central Indiana so I don't have the harsh winter like you northern guys do.
I think the size of the boiler now will still work wonderfully. I have alot of fanning yet to do but atleast I have a start on it.
Title: Re: Gasification wood boiler build
Post by: willieG on September 24, 2010, 05:06:58 PM
one way to look at it is this....forget the normal house btu required that i used..do it like this

you need X amount of btu's to heat your home this winter. if you have one big fire every three or four or five days (what ever it works out to be with your mass storage tank. or if youwere to use a normal sized tank like the other stoves come with, what you have to experiment with is this...by having one large storage tank and one big fire, how many btu's are lost over the time period of which the hot water lasts and then compare to how many btu's are lost on a bunch of start and stop fires. then you will know what way works best.  i am thinking if you were to put the mass storage tank in the home basement what leaked of the tank itself would be leaking to the home and not really wasted?

if you were to heat say two weeks with the small storage tank and then heat two weeks with the mass storage tank (and if the weather was about the same) then you could compare your wood useage and see what way was the clear winner. (i am leaning towards teh mass storage  but that is just my feeling, i have no proof. it would be nice to see an actual comparison on this site

Title: Re: Gasification wood boiler build
Post by: jackel440 on September 24, 2010, 06:05:49 PM
one way to look at it is this....forget the normal house btu required that i used..do it like this

you need X amount of btu's to heat your home this winter. if you have one big fire every three or four or five days (what ever it works out to be with your mass storage tank. or if youwere to use a normal sized tank like the other stoves come with, what you have to experiment with is this...by having one large storage tank and one big fire, how many btu's are lost over the time period of which the hot water lasts and then compare to how many btu's are lost on a bunch of start and stop fires. then you will know what way works best.  i am thinking if you were to put the mass storage tank in the home basement what leaked of the tank itself would be leaking to the home and not really wasted?

if you were to heat say two weeks with the small storage tank and then heat two weeks with the mass storage tank (and if the weather was about the same) then you could compare your wood useage and see what way was the clear winner. (i am leaning towards teh mass storage  but that is just my feeling, i have no proof. it would be nice to see an actual comparison on this site

That is how I was thinking of doing my own tests.I am not worried so much about the quantity of wood consumption,but more on how long the duration between burns would be.
I do think mass storage is the way to go.I have seen lots of good things about it on the Hearth.com forum.
I am a couple years from the mass storage stage of the build.So that part will have to wait for now.
Just going to concentrate getting it built and working for this year.
I hauled a load of logs home today ,and then another load tomorrow after work.So maybe I can start to melt metal with electricity saturday night or sunday. ;D
Title: Re: Gasification wood boiler build
Post by: jackel440 on September 26, 2010, 07:34:35 PM
After hauling wood ,and then helping fix my wifes grandfather's disc so he could get back in the fields.Didn't leave much time for the boiler tonight.I sanded down the top seam and then clamped it up.Mydaughter then came out and decided it was time to take pictures. :D

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Title: Re: Gasification wood boiler build
Post by: jackel440 on September 27, 2010, 07:03:38 PM
Well after rewiring one grinder,and then hooking up the wire feeder to the TrailBlazer I got some metal welded together.My son came out to the shop ,and I helped him lay a few beads on it.Here is a few pics for ya guys.
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on September 28, 2010, 06:39:31 PM
I had to aquare up the Gasification chamber when I got home.Only after I made a run to pick up the Iron Man 2 movie for my son after work.He has been waiting for it to come out on dvd,and asked me at dinner last night to get it. :D
Anyways I over broke one side in the brake and the other not enough.I was able to clamp it to the work bench ,and put some heat on it then use a jack and porta power to square up one side.
I ended up taking the plasma cutter and cutting most of the other side off so I could push it back were it needed to be.
Then I had to grind it and rewled the seams.This piece is 1/4" 70" long so it took a little bit of time and wrestling to get it just right.

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Title: Re: Gasification wood boiler build
Post by: jackel440 on September 30, 2010, 06:47:23 PM
WOW 143 hits on my little projects thread,and I am not even half way done yet.
I got the hole cut in the front wall burn chamber,and the load door extension fabbed and tacked into the wall.Then placed and welded the front wall on.
Starting to look like a furnace a little bit now. :D

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Title: Re: Gasification wood boiler build
Post by: tulenutn2o on October 01, 2010, 06:52:10 AM
I admire a man whose shop looks like mine. My shop is never"clean" always cluttered, and I am always working on something. Great that you are teaching the young one how it's done. :thumbup: :thumbup: Nice shop, great job on the build.
Title: Re: Gasification wood boiler build
Post by: jackel440 on October 01, 2010, 09:05:51 AM
Thanks for the compliments. Yes my shop is always a mess.I always have someone else's stuff in there to fix.there is 2 other cars in there beside the bay the boiler is in.my shop is 40x44x12'.its a work in progress and is paid for as I go.

I feel its important to try and teach my kids skills that they wont learn elsewhere.my son really showed an interest in welding on this project.he had a hood on and was watching me last night.last year he didn't want anything to do with sparks.LOL!
Title: Re: Gasification wood boiler build
Post by: willieG on October 01, 2010, 05:04:23 PM
i just noticed the "spacer" on the gasification chamber...i like a guy whom re-cycles

keep us all in the loop, most of us are rooting for ya
Title: Re: Gasification wood boiler build
Post by: jackel440 on October 01, 2010, 07:56:05 PM
i just noticed the "spacer" on the gasification chamber...i like a guy whom re-cycles

keep us all in the loop, most of us are rooting for ya

LOL! yeah the nieghbor kid was helping me when I was squaring up the gasification chamber,and he looked at me so wierd when I welded 3 of them on there.I just needed them to hold the dimension while i welded it back up.
I just didn't have anything the right length and those old blades on the scrap pile fit the bill.
There is a pic some where of a piece that was going to be the end piece of reese hitch for a Jeep.That I used as a temp spacer.

Got to love working with metal. :thumbup:
More updates and pics to follow tomorrow.
Title: Re: Gasification wood boiler build
Post by: jackel440 on October 02, 2010, 08:57:45 PM
    Ok,I spent alot of time welding seams inside and out the last 2 days it seems.I managed to get the lower gasification chamber welded on tonight.I flipped that sucker up on end ,and raised it up with my lift.I then shimmied my body up inside and welded the seam.What a freak'n pain that was!
     I then cut my lower support plates with relief holes to allow water to flow around the gasification chamber bottom.Plus I put a couple of notches on the bottom side to allow water to be drained from the stove ,and not have any pockets that hold water.I then decided to cut some 90 Degree gusstes to weld onto the support plates to give them strength with the plasma cutter.(Man I love that sucker!)
My Trailblazer ran out of gas on me right as I went to start putting the gussets in.I had to tack them in with my little Miller 135.
Have to run to town tomorrow and get some gas so I can move on to the next step.
any questions just holler, and I will answer best I can.
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on October 03, 2010, 07:29:04 PM
     Alright I got a little more done today.Had to goto town with the family to do some family time.
Picked up some gas for the Trailblazer ,and we're off to the races.
I managed to finnish welding up the gussets on the bottom of the stove supports.I then flipped it back down off it's nose so I could work on the 2 top plates for the Gasification chamber.
      I managed to get them all done after a little custom cutting and grinding to get the fit I wanted.Welded them all up so I could then move onto laying out and cutting the holes for the heat xchanger pipes.
Here is a few pieces of eye candy for you guys. :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on October 06, 2010, 06:55:18 PM
Heat exchanger tubes are welded on.I also have a shot of when I stuck the doors over the front openings to get a little idea of what it will look like.
I then have a shot of where I rigged it up so I could lay it down on her side so I could weld up the heat xchanger tubes easier.
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on October 07, 2010, 07:04:27 PM
Not much of any pics to post tonight,But I did flip this sucker upside down so  could get inside and finnish welding my heat x-changer pipes.Had a small fire burning while I was inside the burn chamber.LOL!If this is a sign I take it as it's ready to burn some wood!
I was alos able to get a smokin deal on my damper actuator on E-bag. :D
I have been trying to get a deal on one ,and keep getting out bid all the time.
I also have a few neat features I plan to install in my furnace.SOme that I have not really seen on any others.I am x-cited to see how they turn out.Could be really awesome to be able to tune the furnace.I will make ya all wait to find out what I have planned :-X
g-night evryone.
Title: Re: Gasification wood boiler build
Post by: bikeralan on October 07, 2010, 11:51:17 PM
I check this thread every day!! excellent job. Is the build something you have had in your head, or are you following a  basic plan?
I am gonna build one next year, we are in the process of moving a house we bought to a different location. It has lots of windows and set up with baseboard heat, so will be perfect for an OWB, but have way enough to do getting it set up this year.
We had a house in town and had a Cozyburn 250, good stove, but liked wood. We are in Northern Lower Mich.
Good luck on your build, and thanks for the step by step, very interesting and informative, great job! :thumbup:
Thanks,
Alan
Title: Re: Gasification wood boiler build
Post by: jackel440 on October 08, 2010, 08:30:01 AM
bikerAlan
   Hey thanks for stopping by.There isn't alot of good pics on the net of guys building theirs. I had planned to share what I did on mine. :thumbup:
   I have planned on building a boiler for along time.over 5 yrs.I just finally was in a position to make it happen.I have designed atleast 3 different styles from researching other stoves and my own ideas.I have mixed and matched the features I like to get what I think will work best for me.
I also waited to see how nice these gassifiers were going to work.no point spending the time building something when I can build a better one.
I need to heat my home,shop and eventually hot water.
I have designed my build and made my own drawings. Not everything has been exact to my prints but have made them work out nicely.
I have been working on door hinges and my door locks.got most of those pieces cut out and ready to weld together.
Title: Re: Gasification wood boiler build
Post by: jackel440 on October 08, 2010, 07:00:00 PM
Update...
   I flipped the boiler back up right tonight after doing a little welding and grinding on the inside.I got my 8" bypass pipe today from my buddy who has a Millwright shop.Laid out the location  and then took my Plasma Cutter and cut the hole for it.Hole was a perfect fit on the first try. :thumbup:
I then put it in the hole and welded it all up.
So now I have one more piece to trim to fit ,and then it will be time to move onto the fabrication of the tank.I hope  :o
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on October 08, 2010, 07:09:52 PM
I guess I should have posted this before the last set of pics,but here is a few parts I got brought home today. :D
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on October 10, 2010, 06:33:17 PM
Well got up today and had to clean out part of the shop so I could get some clear floor space.I then layed out the 2 pieces I had to weld together to make the bottom and one side.I had to add a 12" piece to my 48" wide sheet to get my 60" long tank. :o
I then had had to quite and go with my family to the battle of Missisnewa 1812.Was a good time seeing all the period reinactors and the crafts and food.
I got home did some grinding on some welds to smooth out the tank floor seam.Then I picked the burner assembly up with chain falls ,and then slid the tank bottom and side piece under it.Then me and my daughter proceeded to let the burn chamber down with the chain falls. :thumbup:
Then the kids decided we should do some picture taking. :pic:


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Title: Re: Gasification wood boiler build
Post by: jackel440 on October 10, 2010, 06:36:32 PM
Ok here is a couple more pics of us being silly. :pic:

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Title: Re: Gasification wood boiler build
Post by: bikeralan on October 11, 2010, 01:42:40 AM
Good lookin support crew you have there! ;D I have four that are now 13 to 20, 2 boys, 2 girls.
They have been a lot of (help) over the years also lol. Keep up the good work.
Title: Re: Gasification wood boiler build
Post by: jackel440 on October 11, 2010, 06:21:29 PM
Centered up the burn chamber on the tank bottom and stitched it down.I then proceeded to cut holes on the heat xchanger shroud for the return water pipes.Next i cut pipes to length and threaded on the elbows.I then welded them in position inside and out.
Then I put the shroud back on and welded it up solid.
Next step will be to work on the back panel.I have to put a tranny in my cousins car the next day or two.So there might not be much progress on this little wonder of mine.
On to the pics!
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on October 11, 2010, 06:34:04 PM
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Title: Re: Gasification wood boiler build
Post by: jackel440 on October 18, 2010, 06:53:45 PM
Ok ,here is a little update for ya guys.Sorry no pics till tomorrow.I made a trip to Indy today and picked up my skid of 100 hard refractory brick and a 55# tub of brick mortar. :D
Not quite yet ready for it ,but I had to go get it.Got my cousins car done ,and went camping over the weekend.So hopefully now I can get back to finnishing this sucker up soon.
Title: Re: Gasification wood boiler build
Post by: jackel440 on October 19, 2010, 06:37:34 PM
Alright I miss spoke,No pics tonight eother as I left the camera in the shop.I wrenched my back lifting the top and side piece  on for a test fit.So I am not going back out to get it.
I did get the return pipes cut and threaded and the holes cut into the top piece.I will try for pics tomorrow night. ;)
Title: Re: Gasification wood boiler build
Post by: tulenutn2o on October 20, 2010, 06:57:40 AM
Bummer on yer back. I am in same boat, hope all is well and not serious. Keep pics coming.
Title: Re: Gasification wood boiler build
Post by: jackel440 on October 20, 2010, 06:55:11 PM
OK here is some pics to update you o what has been done.
A couple shots of the back wall with holes cut in it.Then one of my pipe threader and some 1" pipe.
Then we have a shot of the back wall with the return pipes trial fitted.
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on October 20, 2010, 07:05:10 PM
I also had a package show up with my damper actuater I ordered off the Ebag.Got a smoking deal on that little marvel.Then Monday I went and got my 100 hard refractory brick and mortar.
I got the two  top and side pieces welded together.After a few trial fits to get everything to line up just right I finnish welded the seam together.
Here is a few pics :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on October 20, 2010, 07:15:41 PM
Ok here is a shot of the template on the top so I could cut the holes for the pipes.
I then threw in a shot of a Hossfeld bender i picked up for $300. :D
Then there is a shot of my Taylor Dunn and skid loader on my trailer.I brought the flatbed home from the campground and the skidloader from thee woods.The wife said she needed it back home so she could get a few things done. ::)
Got to break up the boring boiler build pics with some different stuff.LOL!
 :pic:

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Title: Re: Gasification wood boiler build
Post by: rosewood on October 20, 2010, 07:20:15 PM
lookin good! some posts back the question of capacity was brought up, the more storage the better! my homeade has 1200gallons.the first burn to raise temp at startup 70deg to 185 deg took 6.5 hours . at a 20 deg diff it only takes about 45 min to 1 hour to reheat to temp. 1 load of wood a day in 3'x5' firebox. when building mine i got alot of neg feedback from ''store bought'' owners that said it will never work right.in dead of winter 20 deg average, furnace cycles 4-5 times a day, whereas less capacity units cycle 9-12 times a day for shorter burn periods,plus more smoke, also i recently went away for 5days temps got in mid 40s at night,before i left i brought temp up to 195, turn t.stat in house to 59 . came home to 140 deg water,point is thermal storage is key. all the years ive been at this site ive never heard anyone talk about GARN wood furnaces, lets face it there the most effiecent factory built units made,why?..cause of there unique firebox and exhaust design, and water capacity 2000gallons. well good luck with the rest of your project.
Title: Re: Gasification wood boiler build
Post by: jackel440 on October 20, 2010, 07:58:03 PM
Thanks Rosewood.
I completly agree with you that storage is the key.Everyone has thier theorys on what works.I think storage would work best and thats what I plan to do.If guys up north are doing it like crazy then there is some truth to it.I have heard and read lots of info on it at the hearth site for alot of years.
I am enjoying the project ,but time is running out for me.I am out of LP and its getting cool here.So I need to get this baby running soon.
Title: Re: Gasification wood boiler build
Post by: jackel440 on October 21, 2010, 06:37:14 PM
Well tonight I accomplished quite a little bit figuring I ddn't get home right after work.I managed to weld 2x2 angle to the sides of the tank walls to strengthen them to help from bowing out.I fabricated the float pipe for the water level float to go in.I then got the hole cut for that pipe in the top ,and then fitted it the whole thing back together.
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on October 23, 2010, 09:01:00 PM
Well since we last talked about my little project here.I decided I didn't like how a few things were looking so I cut a few things apart ,and then modified them a little. >:(
I am now back on track and got quite a bit accomplished today after work.I managed to get the 2 air passage pipes welded into the back of the burn chamber.I then finnished my piping on the back wall and put the wall on.I also welded in anti ballooning braces on the sides of the tank.
Now onto a few pics
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on October 24, 2010, 07:10:58 PM
Well I managed to get alot done today even though it doesn't look like much.I layed out the front cutouts on the front wall for the upper and lower door chambers.I welded in the last of the anti balloning braces on the sides.Got the front wall fitted on and started weldingup all the tank seams.
I have a shot of the air pipes inside the burn chamber.I will finnish fabbing the rest of the tubing for that later.
Now what you all have been waiting for,More pics
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on October 24, 2010, 07:24:04 PM
Here is few more misc. pics.
a pic of the kids carving thier pumpkins today.Then a shot showing where water can flow around the back of the heat exchnger trough and between the back tank wall.
 :pic:

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Title: Re: Gasification wood boiler build
Post by: bikeralan on October 25, 2010, 02:06:19 AM
Lookin good! :thumbup: , I don't know who wants to see it completed more, you or me lol. ;D
Title: Re: Gasification wood boiler build
Post by: jackel440 on October 25, 2010, 06:41:04 PM
nothing much new to report tonight other than welding alot of seams :bash:
I so hate overhead welding.Only managed to catch myself on fire once. >:(
Oh well thats all part of it.Still have alot of seams to work on tomorrow.I am grinding them back down and going over the ones that look questionable as a posible leaker.
So maybe I will have something interesting to post tomorrow
So tune in tomorrow,same time ,and same place....... :thumbup:
Title: Re: Gasification wood boiler build
Post by: tulenutn2o on October 26, 2010, 05:46:58 AM
The craftsman is his biggest critic. :) Great job, great pics, timely updates. You are the man! :thumbup: :thumbup:
Title: Re: Gasification wood boiler build
Post by: jackel440 on October 26, 2010, 06:55:23 PM
Ok folks we had a heck of a day.Storms came through and we had to evacuate the plant to storm shelters for a tornado watch.Nothing like a couple hundred people shoved into the shower rooms. :bash:
Anyways I got home and finnished welding a few seams ,and around the heat x-changer pipes.Grinded some more ,and then finally called it good.
I then blew a hole in the bottom of the tank ,and welded in a coupler for a tank drain.(Which I will need to flush all the crap out before using it!) :thumbup:
I am just about ready to pressure check the tank.I am one ball valve short so I will pick that up tomorrow.
I hope to start building the frame for it to sit on tomorrow if I have enough material to make it out of.
Now onto a few pics......

 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on October 27, 2010, 06:38:01 PM
Tonight was an eye opener for me :bash:
I fabricate platforms, machine parts,guarding and such everyday at work.BUT building a tank to hold water is a pain in the A##!!!!!!
I finally got the rest of the valves plumbed to the back of the tank.Hooked up a pressure guage and air line to another valve then proceeded to pressurize it to check for leaks.
All I can say is I am no pressure vessel expert.I have a lot of spots to rework.Places that should have never leaked are letting air past I was actually shocked at a few that weren't leaking though. ::)
Looks like I am going to spend the weekend with my friend the grinder ,and doing a little bit of rework.I have to admit I didn't think it would have so many spots that would pass air.Oh well,thats how it goes sometimes.
I did manage to make the air box for the back of the stove.Just need the blower so I can finnish it.
good night everyone.....
Title: Re: Gasification wood boiler build
Post by: mober on October 27, 2010, 06:44:41 PM
thats why there is a trade for pipe fitting pipe welding :thumbup:
how many psi are you putting on it>?
and did you did 3 passes on the welds?
Title: Re: Gasification wood boiler build
Post by: willieG on October 27, 2010, 07:12:21 PM
the style of furnace it looks like you are building has many square corners. i would not recomend much pressure at all, maybe 5 to 7 pounds any more and your square tank will try and go round.

also if you are dong position welding for this project i would hope you are using dc 7018 for good strong leak proof welds...and the rod should not be left out on the table but kept warm and dry before use

good prep is a must

aint learning the hard way more fun!
Title: Re: Gasification wood boiler build
Post by: jackel440 on October 27, 2010, 07:48:30 PM
Well I  am a Millwright ,definatly not a pipefitter.LOL!I only put about 5 to 8 psi in it.I have enough leaks that it's not going to pop. ::)
I guess it's not too bad,but just an ego buster when I thought I had this thing whipped.LOL
Wille I am using ER70 wire in a wire feeder for this project.I have to admit I didn't do much mig welding till about a year ago.As my plant just mainly had all SMAW machines.The new plant I am at has all MIG machines for us maintnance guys. :D
I had a Miller 135 I used for light stuff and bodywork.I got this wire feeder for my trailblazer for this project.It has performed really well,but just mainly me not using proper technique.I will have the leaks fixed and be back on the road here soon. >:D
Title: Re: Gasification wood boiler build
Post by: jackel440 on November 03, 2010, 06:51:57 PM
Well good news to report.I finally got all my seams sealed up.I started on making a frame for it the boiler to sit on.I wanted to get all new steel for the base,but time and money dictate I use what I have here on the farm.
I also have most all the controls and wiring worked out with a friend of mines help.I have to mount the controllers in the box and do some wiring.
Didn't take any pics tonight ,as there wasn't much to show yet.
later everyone :thumbup:
Title: Re: Gasification wood boiler build
Post by: jackel440 on November 04, 2010, 07:48:57 PM
Ok did alot of grinding old rusty channel iron,and then welded 2 pcs together to make a set of fork pockets.I then cut a 10" channel I had in half for the 2 frame rails for my boiler to sit on.I have a pic of them mocked up not welded together yet.
I then finnished making my water temp thermocouple holder.Looks kind of like a gun barrel on the end with the holes drilled in it. :D
I then have a little teaser shot of my control panel that I have been putting together.
Hope you all enjoy. :thumbup:
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Title: Re: Gasification wood boiler build
Post by: jackel440 on November 05, 2010, 07:07:39 PM
Frame is made wth fork pockets welded in.I moved the fork pockets together from what I originally had.I was going off the dimensions of 15K # Hyster trucks carriage.I checked on a 6K# truck at work and it maxed out at 36" outside of the forks.So I went with that spacing.
I welded a 10 guage front panel to the 2 frame rails.I am holding off on putting the back panel on because I have to pick up some B-deck to slide in the bottom of the frame rails to hold in insulation and hopefully keep the mice out.
I then got the boiler lowered down onto the frame.then centered it up and tomorrow night I am going to weld it down.
Next I want to drag it outside and fill it with water.See if I got all the little leaks fixed.I got them sealed up with air in the tank,but I want to fill it with water anyways just so I can sleep at night. :o
Well anyways here is a few pics.
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Title: Re: Gasification wood boiler build
Post by: jackel440 on November 07, 2010, 05:24:45 PM
well had to work over tonight so I didn't get too much accomplished.I did start fabbing the exhaust bypass box.
Hopefully more to show tomorrow night.
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Title: Re: Gasification wood boiler build
Post by: jackel440 on November 08, 2010, 05:54:53 PM
Well I finnished fabbing most of the smoke bypass box tonight.I think it came out fairly nice.I made the door from 3/8" plate scrap I had laying around.I then had to weld 3 holes shut in the middle of it.Made a rope seal channel and put in the rope seal.Took some pipe section and two  1/2" shoulder bolts for my pivot point.
I decided not to cut the hole for the exhaust stack as I have not yet decided on the size i am using.
Well here is a few more pics for your entertainment.....
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Title: Re: Gasification wood boiler build
Post by: jackel440 on November 08, 2010, 05:58:15 PM
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Title: Re: Gasification wood boiler build
Post by: jackel440 on November 09, 2010, 07:10:19 PM
Well we had a good night tonight.Temps were back up in the 70's :D
I managed to fill the boiler full of water to double check for any leaks.I found one spot that was just barely sweating a little moisture.So I am pretty happy about that.
I then drained all the water back out.Made some brackets that the control panel mounts ,and then decided on a position and welded them to the tank.
I then decided on a position for the thermocouple tube to go into the water tank.Fired up the plasma cutter and made an oval hole in the top.Cool thing was that when i finnished the cut the air blowing into the tank made the cut out piece blow out onto the top of the tank and not fall inside. :thumbup:
I welded the tube in just were i wanted it.I have it angled as my thermocouple is about 20" long.I wanted to be able to easily pull it out if I need to replace it after the outer enclosure is built.
I then welded up the corners on the load door.I need to get the doors built and mounted.
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Title: Re: Gasification wood boiler build
Post by: jackel440 on November 09, 2010, 07:19:49 PM
I also got the bypass box finnished.I drilled and tapped all the holes to bolt the lid on it.I made it removeable so when it comes time to replace the rope seal on the bypass door it will be easy to get to.
I welded it onto the top of the tank.I then put the bypass door in so it is done.Only thing left to do is cut the exhaust stack hole ,and mount a rod to open the bypass door.
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Title: Re: Gasification wood boiler build
Post by: jackel440 on November 14, 2010, 07:00:01 PM
Well I got some work done on the boiler tonight finally.I had spent the last few days redoing the outside wall on my stable.Had to pull off the old plywood and the old girt boards.Put on new girts,OSB,and then metal siding.Then back filled the side with gravel.
So today after getting home from work I managed to fabricate my hinge assembly for the burn chamber door.Weld in the channel strips to hole the rope seal.drill and mount the hinge,and adjust the door.Boy was I pleased when it swung open real nice! :D
I then started on the lock bracket.Got it designed and cut the pieces to get the fit I wanted.I will mount it tomorrow.
I will throw a few pics up here for you guys to get you caught up on the progress.
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Title: Re: Gasification wood boiler build
Post by: jackel440 on November 14, 2010, 07:08:18 PM
Ok here is a few of the hinge being built and of the door mounted and swung open. :thumbup:
The door is not yet finnished.I still have to weld on an insulating box on the inside of the door.Plus fill it with K-wool so it will be insulated.I will do that tomorrow.
I also have some more fittings I need to weld to the tank.I have the day off tomorrow so I plan on trying to get a lot done.(I HOPE)
later everyone.....
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Title: Re: Gasification wood boiler build
Post by: bikeralan on November 15, 2010, 02:45:42 AM
Lookin good! bet you can't wait to get her goin'
Title: Re: Gasification wood boiler build
Post by: jackel440 on November 15, 2010, 05:47:14 AM
Lookin good! bet you can't wait to get her goin'

Your right I can't wait.I need to get some heat going to my house!Luckily we have had some mild temps for this time of year.I hope to have it all done in 2 weeks.Just depends if all my parts ever get here before then. :bash:
Title: Re: Gasification wood boiler build
Post by: jackel440 on November 15, 2010, 07:16:00 PM
Well I finnished most of the door today.fabbed the dome frame for the inside to hold the K-Wool to insulate the door.Spent most of the day working out the details of that.everything is 1/4" material ,and boy did this door get heavy. :o
After welding the dome together I then welded studs to the door to hold the dome on so I could remove it if I needed to for some reason.Took a little doing to get everything to align up.After the studs were in the right location ,and welded solid.I then put on three layers of K-Wool to insulate the door.
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Title: Re: Gasification wood boiler build
Post by: jackel440 on November 15, 2010, 07:24:23 PM
Next up I then put the dome down on top of the studs and K-Wool.Then tightened it all down with Brass nuts on the 5/8" studs to hold it all together.
I finnished the handle and the lock mechanism ,and got them mounted also.
I then welded in some couplers fo rthe Stainless Steel dry wells I had got ahold of for my high temp aqua stat ,and one down low where the pumps mount to see what the temp going to the house is.
I had a heck of a time with those dry wells.They were no standard pipe thread,but were Standard British pipe thread.So I had to order the couplers through my buddys shop.
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Title: Re: Gasification wood boiler build
Post by: jackel440 on November 16, 2010, 06:01:45 PM
Tonight I was able to get an angle iron frame welded on to the rear of the stoves gassification chamber access hole.I then made a door ,and then drilled the holes and welded in studs to hold the door on.I then made a nice horse shoe handle to use to be able to remove and install the access cover. :thumbup:
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Title: Re: Gasification wood boiler build
Post by: jackel440 on November 19, 2010, 07:35:09 PM
Well I have been working 12 hours the last half of this week so nothing much has gotten done on the boiler.I did make a few pieces but nothing spectacular until today.The Fedex driver brought and dropped off the next piece of the puzzle today.
My blower is finally here after a couple weeks of fighting with the credit card company on getting my order approved. :bash:
I finally have it ,and got it for a good price.
I paid $97 with shipping for my Dayton blower.Ball bearing motor and over 500 cfm to feed air to both chambers. :thumbup:
Grainger wants over $160 for this blower before shipping.I picked it up at USA Industrial supply.Nice folks to deal with.
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Title: Re: Gasification wood boiler build
Post by: quik_vw on November 21, 2010, 06:41:58 PM
I know your getting anxious to fire this baby up!  It's been a pleasure to follow your progress and I find myself on the edge of my seat waiting for feedback on the operation and performance of this jewel.  I appreciate you taking the time to share the build with all of us here.  Keep up the good work and I am sure your efforts will be greatly rewarded............
Title: Re: Gasification wood boiler build
Post by: jackel440 on November 21, 2010, 07:47:52 PM
I know your getting anxious to fire this baby up!  It's been a pleasure to follow your progress and I find myself on the edge of my seat waiting for feedback on the operation and performance of this jewel.  I appreciate you taking the time to share the build with all of us here.  Keep up the good work and I am sure your efforts will be greatly rewarded............
Yes i am ready to light a fire already.I have been working 12 hours all week and just haven't been able to get much done on it.President Obama and VP Biden are coming to our plant on tuesday.It has been a mad house preparing for them.As a millwright in the plant I have been making all kinds of stuff.We made a blast shelter for them to get behind just in case something happened. ::)
I am excited to have them come to our factory and tour it.
I will be having a 4 day weekend after wednesday.So I would say look for some major progress pic this weekend as I plan to get alot done.
Title: Re: Gasification wood boiler build
Post by: quik_vw on November 22, 2010, 06:03:18 AM
Obama was here to address our high school graduating class, so I can imagine what your going thru, it was interesting watching the scout planes and helicopters checking rooftops.  Also, those Secret Service guys aren't no joke!  The told the homeowners near where his helicopter landed NOT TO BE SEEN IN ANY UPSTAIRS WINDOWS...........because the consequences would not be good...lol
Back to your project, your in the home stretch and I am sure 4 days will allow for much progress even with a nap from a large holiday meal.  I too hope to get lots done this week.  I am interested to see how your fire path will work, ie; size of opening to the secondary burn chamber etc.  I am assuming the by-pass door is for an upward draft upon start up?  Your so close, I am sure you will not get in a hurry and bring this baby home!
8 acres? think that would be enuff to work out the bugs in my processor?  I am hoping to do that in 5 acres or less. :-\  I have some cross members to add to the tongue section and the log trough will tie it all together, I tend to build on the "heavy" side.  When it's done I think the question may be will the 3500 lb. axles be enough?  Keep pressing on bro.
Title: Re: Gasification wood boiler build
Post by: jackel440 on November 24, 2010, 07:59:15 PM
quik-vw, That sounds awesome having the pres come to the school.
He stopped by a local grade school on his way to our plant.Very memorable for all those kids and teachers when the limo stopped in the middle of the street and he got out ,and came over to them.
I will be back on the boiler after my mid day family get together if I can move! :o
I did get a call from my friend at work,and he has ordered all my pumps valves and underground pipe.plus my plate exchanger and some other stuff.I have to go pick it up saturday morning.So it looks like I will be on a road trip up north to get that stuff.
So sit tight and maybe if your all good I will have some pics to post.LOL! ;D
Title: Re: Gasification wood boiler build
Post by: jackel440 on November 25, 2010, 07:30:01 PM
I managed to get a little bit done tonight.I engineered as I went to try and get my damper assembly together,and I must say it turned out to be a success.I have to make a few more pieces to finnish it up all the way,but I did have it under power.Sure did open and close real nice.
this box will mount on the back of the boiler.The fan mounts to the bottom.When the controller kicks the the boiler on.It will open the damper ,and start the fan.when the water temp gets to the set point.The fan shuts off ,and then the damper closes to seal off all air.
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Title: Re: Gasification wood boiler build
Post by: jackel440 on November 25, 2010, 07:31:26 PM
another shot of the damper actuator mounted.
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Title: Re: Gasification wood boiler build
Post by: jackel440 on November 25, 2010, 08:03:05 PM
Here is a little video I took of the damper in action.I have to say it works pretty good.
Belimo Damper actuator mounted to damper in airbox for wood boiler (http://www.youtube.com/watch?v=3A3IAgtgWxU#)
Title: Re: Gasification wood boiler build
Post by: jackel440 on November 28, 2010, 06:46:36 PM
Well I didn't get near what all I wanted to get done.Dang family get togethers and black friday :bash:
I did run up to Shipshewana and pick up my underground pipe,valves,fittings,rope seal,water treatment,and some other stuff.They didn't have my pumps in stock or the wye strainers.Going to ship those to me.
I did get the damper box tacked onto the back of the furnace.Then tonight I started laying brick into the gassification chamber. :thumbup:
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Title: Re: Gasification wood boiler build
Post by: jackel440 on November 28, 2010, 06:51:09 PM
Some more hard brick installed :thumbup:
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Title: Re: Gasification wood boiler build
Post by: macmgfd on November 28, 2010, 09:37:50 PM
Jackel, I to am getting ready to build a gasification boiler. I am finishing up the planning stages but I have a lot of ideas that are similar to yours. So if you don't mind I may hit you up about some of your ideas. What is the purpose of your thermo couple in the secondary burn chamber?
I was also thinking of a damper similar to yours but with a different actuator but I am a little worried about it leaking air around the shaft where it pivots. What is your thinking on that?
Title: Re: Gasification wood boiler build
Post by: jackel440 on November 29, 2010, 07:57:16 PM
Jackel, I to am getting ready to build a gasification boiler. I am finishing up the planning stages but I have a lot of ideas that are similar to yours. So if you don't mind I may hit you up about some of your ideas. What is the purpose of your thermo couple in the secondary burn chamber?
I was also thinking of a damper similar to yours but with a different actuator but I am a little worried about it leaking air around the shaft where it pivots. What is your thinking on that?

OK first off.The thermocouple in the secondary chamber has 2 uses.1st is I hope that I can control the burn by tuning the amount of air going to the lower chamber with some plates witch I have not yet fabricated.I hope that I can tune the gassifying chamber to get the most efficiancy out of it.2nd is it will be cool to see what temp I actually get.
Now on the shaft I have a seal to keep any air from getting past the shaft.The shaft only goes the side of the box the damper is on.the other end sits in a bracket thaat is welded inside.I made a lock collar that goes on the shaft to go on the other side of the box to keep the shaft in the proper location.Now on that collar I welded a pipe coupler to one side.that side goes up against the inside wall of the air box.I stuffed the area between the shaft and the coupler with rope seal.Then slid the lock collar assembly up against the wall and locked down the set screws.wallah!no air leakage....
I am taking a break ,but am going back out to the shop.temp got into the 50's so I am working all night on as much as I can get done.I have quite a few pics so far.So either I will get some up tonight or tomorrow.Later...... :thumbup:

Title: Re: Gasification wood boiler build
Post by: jackel440 on November 29, 2010, 10:19:50 PM
my underground pipe.I was going to make my own.I could get the price down to $3.80 ft if I did it myself.I got this for $3.20 a foot.Cheaper plus I didn't have time to make my own.
Then there is my pump flanges with shut offs,and some ball valves,and the rope seal.Oh and there is a Watts mixing valve also.
I got the upper level floor in tonight also.....
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Title: Re: Gasification wood boiler build
Post by: jackel440 on November 29, 2010, 10:22:27 PM
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Title: Re: Gasification wood boiler build
Post by: jackel440 on November 29, 2010, 10:30:19 PM
The big brown truck finally delivered my water level switch. :thumbup:
I picked it from HGR sales which is an Industrial overstock seller.I bought my Taylor Dunn flatbed from them.They have lots of cool stuff.
I had to cut the float arm down to get it in my tank where I wanted it.I had to weld half of a 2 1/2" union to the side of the tank for the switch to thread into.
This switch is going to work nicely for what I have planned for it. ;)


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Title: Re: Gasification wood boiler build
Post by: jackel440 on November 30, 2010, 08:49:49 PM
A little more brick work done tonight.I had to take the wife to get some teeth cut out today.SO she was drugged up .I didnt get much done ,but what I did get done was needed to be finnished.I rigged up my circular saw with a diamond blade to cut my bricks.worked out pretty good too.I did learn that a spray bottle with water  spraying on the blade every now and then made a world of difference.
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Title: Re: Gasification wood boiler build
Post by: jackel440 on December 01, 2010, 03:34:42 AM
Here is a little video of me cutting one of the hard brick for the boiler :thumbup:
Cutting refractory brick (http://www.youtube.com/watch?v=sTuwNamgT3w#)
Title: Re: Gasification wood boiler build
Post by: bikeralan on December 01, 2010, 04:56:18 AM
Lookin good!, looks like your getting closer. On your last pic of the brickwork, what ia the white filler on the sides? expansion joint? or just filler?
Hope the wife is doing okay, I would as soon take an ass kicking as go to the dentist lol
Title: Re: Gasification wood boiler build
Post by: jackel440 on December 01, 2010, 06:43:57 AM
My wife is doing really good.she was up last night and ate dinner then got on the computer.I also hate going to the dentist myself.thank goodness for drugs!
The white material is K-wool insulating blanket.I forget the temp rating on it off the top of my head.I decided to line the upper secondary chamber area to keep the heat in the firebrick.that way the stove would gassify quicker upon start of a burn cycle.I think if the brick was mortared right to the steel it would pull the heat right out of the brick too quickly while it was idling.I guess we shall see what happens when it is running.
Title: Re: Gasification wood boiler build
Post by: tulenutn2o on December 01, 2010, 08:40:30 AM
My wife is doing really good.she was up last night and ate dinner then got on the computer.I also hate going to the dentist myself.thank goodness for drugs!
The white material is K-wool insulating blanket.I forget the temp rating on it off the top of my head.I decided to line the upper secondary chamber area to keep the heat in the firebrick.that way the stove would gassify quicker upon start of a burn cycle.I think if the brick was mortared right to the steel it would pull the heat right out of the brick too quickly while it was idling.I guess we shall see what happens when it is running.
Wouldn't having brick glued directly give you more btu's getting into the water where you want it to go? I know there is a balancing act between drawing heat off versus gasification but I think it is a mute point in this instance. Like your build. How many hours and $$$ you have in it now?
Title: Re: Gasification wood boiler build
Post by: jackel440 on December 01, 2010, 09:22:33 AM
The theory is that the insulated burn chamber will hold the heat longer between cycles of burning.which will make the gassification burn start sooner.the bottom level is mortared right to the steel.even with the insulation there will be plenty of heat transfer I believe right there.
Title: Re: Gasification wood boiler build
Post by: vpd66 on December 01, 2010, 11:38:34 AM
My thought is that Gasification takes high heat 2000+ degrees, so you need a chamber that will hold up to that sort of temperature. Any attempt to pull heat of the Gasification chamber would have to much of a cooling affect and you might not get complete Gasification burn. All the heat for heating the water should come from the exhaust coming from the chamber. This is why regular OWBs don't burn very clean, too much water surrounding the firebox and cooling the burn. I'm loving your build. Keep up the good work and I hope it works out for you. I too would like to build one in the future when my regular OWB dies. For me to go out and buy a Gasification unit would take about 15 years to get a payback, and then would the furnace last that long??? I doubt it.
Title: Re: Gasification wood boiler build
Post by: jackel440 on December 01, 2010, 02:42:01 PM
Yes the burn temps for the gasification chamber should start just above 2000f to 2700f from what I have researched.The insulated chamber should help create and maintain those temps.
I have a second pass in the lower chamber that will allow the brick to absorb heat ,and transfer it to the water tank.then the exhaust will exit through 6 heat exchanger pipes up the back of the stove.then exit out the rear stack.
Title: Re: Gasification wood boiler build
Post by: jackel440 on December 01, 2010, 08:08:02 PM
   Well tonight I cut a couple 45 degree wedges to put in the back corners to help transition the air flow around the brick seperating the air injection pipe and the secondary burn chamber.I then cut the back 2 blocks for the air pipe to go through.you can see in the second picture the piece of steel tubing which is where the air pipe goes in.
   Hopefully more will get done tomorrow night.We have snow on the ground now. :bash:
I am using kerosene till this baby is working.Just not enough hours in the day. >:(
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Title: Re: Gasification wood boiler build
Post by: rosewood on December 01, 2010, 08:11:54 PM
do you plan on using forced draft or draft inducer. iwould think a inducer would be more desireable to pull thru the length of tubing.
Title: Re: Gasification wood boiler build
Post by: jackel440 on December 01, 2010, 08:36:05 PM
forced draft.You have to pressurize the burn chamber to force the smoke gases to go down into the secondary burn chamber.Then you have to force oxygen into the secondary burn chamber to help with combustion of the wood gases.So no a draft inducer wouldn't work.Plus the fan I am using can move upto 550 cfm of air.Thanks for the interest.Always looking for ideas outside of the box I am stuck in :thumbup:
Title: Re: Gasification wood boiler build
Post by: Scott7m on December 02, 2010, 08:14:08 PM
My thought is that Gasification takes high heat 2000+ degrees, so you need a chamber that will hold up to that sort of temperature. Any attempt to pull heat of the Gasification chamber would have to much of a cooling affect and you might not get complete Gasification burn. All the heat for heating the water should come from the exhaust coming from the chamber. This is why regular OWBs don't burn very clean, too much water surrounding the firebox and cooling the burn. I'm loving your build. Keep up the good work and I hope it works out for you. I too would like to build one in the future when my regular OWB dies. For me to go out and buy a Gasification unit would take about 15 years to get a payback, and then would the furnace last that long??? I doubt it.

huh? 15 years?   what planet do you live on where they supply nearly free fuel? lol

golly moses.   i live in ky and I can easily spend 3500 - 4000 per winter just on heating costs.   

there are some really nice gasification units in the 8k price range as well!
Title: Re: Gasification wood boiler build
Post by: vpd66 on December 02, 2010, 09:46:41 PM
Well, my house is only 1200sf and I built it 5 years ago. I installed a 94% efficent LP furnace and it only takes about 1 1/2 tanks of LP a winter to heat my house (500 gallon tank). I found a deal on a used OWB and installed it 3 years ago. So far the only cost in firewood is gas and oil for my chainsaws. I figure about 5 gallons a year. I have woods and have plenty of firewood. A guy I work with lives a 1 mile down the road and owns 80 arces that was select cut August 2009 and he is letting me cut all the tops I want. I haven't bought LP in 3 years so I don't know the current price, but I'd guess it would cost me $600-$700 a year to heat my house. So if a new Gasification boiler is $8000.00 you do the math on how long it would take for me to get a return on that investment......
Title: Re: Gasification wood boiler build
Post by: jackel440 on December 05, 2010, 02:58:06 PM
Now back to our regularly scheduled program. >:D
I finnished most of the brick in the gas chamber today.Going back out after i eat some ham and beans to get a little more done tonight.I will then post up some more pics.
Now for your viewing enjoyment......
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Title: Re: Gasification wood boiler build
Post by: bikeralan on December 05, 2010, 04:57:35 PM
Lookin good! It's snowing like crazy up here in Mich., going to pick up my stove sometime this week, won't be using it till next yr.
You have to be stoked getting so close!
Title: Re: Gasification wood boiler build
Post by: vpd66 on December 05, 2010, 05:49:55 PM
Looking good. So the two sqaure holes in the top layer of brick are the nozzles? How did you determine the size to use? Are you going to let the wood and coals lay on the top layer of bricks? Or is there going to be a grate for the wood and coals to lay on? the square tube in the back must be where the secondary air enters? and the pipe coming in the side is for your temp probe? Sorry for all the questions, but this is what I've been waiting to see and how you were going to do it.
Title: Re: Gasification wood boiler build
Post by: jackel440 on December 05, 2010, 07:49:06 PM
Yeah we got about 3" of snow here in the last couple days.
Yes the 2 rectangular slots are the nozzles for each path underneath the firebox.Yes the tube in the back is where the combustion air will enter the back side of the gas chamber.
The tube is for my thermocouple to check the gassification burn temperature.This will not be for  controlling the furnace.Just to use as a tool to check the efficiency of the burn.
There will be a 1" steel plate in the bottom of the burn chamber to protect the fire brick.They wouldn't take any punishment of logs being thrown on top of them.
Oh,and I got layed off at work so I will be spending my time hopefully finnishing this up this week. :thumbup:
Just sucks its right before the holidays. :bash:
Title: Re: Gasification wood boiler build
Post by: vpd66 on December 05, 2010, 08:15:43 PM
Sorry to hear about the layoff. Is it permenant or temparory? Things have been tight where I work the last 2 years, but this year we've been very busy.
Title: Re: Gasification wood boiler build
Post by: jackel440 on December 05, 2010, 08:38:43 PM
Sorry to hear about the layoff. Is it permenant or temparory? Things have been tight where I work the last 2 years, but this year we've been very busy.
The rumor is it is only supposed to be for one week.possibly 2.The assmbly plant is slow on thier launch.So they aren't taking many transmissions there as was scheduled.We are running out of racks so they cut 3rd and 2nd shift down to slow production for a week or 2.Our plant is actually running at full tilt till the assembly plant slow down.But hey thats fine with me.I would rather the assembly plant fix whatever issue they have before assembling cars. :thumbup: Managment has finally got thier head out of thier posteriers. :o
Title: Re: Gasification wood boiler build
Post by: vpd66 on December 06, 2010, 10:24:46 AM
Good to hear its not permanent. I would gladly take a week or two off to save jobs. My company usally has "volutary ferlows" for a week or two around Febuary-March, but it looks like we have enough work to keep us busy this winter. Good luck
Title: Re: Gasification wood boiler build
Post by: rosewood on December 06, 2010, 03:29:38 PM
have you been saving your receipts? whats the tally up to? if your work don't call you back you might be building those things for a living! im sure you could sell a few on here to some guys that are sick of there old smokeys. :thumbup:
Title: Re: Gasification wood boiler build
Post by: jackel440 on December 06, 2010, 07:36:27 PM
No tally on my cost yet.I don't want to know :o
I did finnish up the last couple of brick I had to cut and put in.I then had to cut my lower door apart and modify the outside to make it a little bigger than it's original size.I bent it up in the brake before I bent the bottom chamber.Just wasn't going to fit the way I wanted it to.
I then proceeded to start making the hinge and the lock mechanism.got those pieces done,and ready to be welded together tomorrow.I decided to quit for the night.The salamander can only get the shop up to 50 degrees.It's like 9 degrees outside here.My shop is fairly big,and not insulated all the way yet.I was tired of listening to it run.So I shut it off and worked till i got cold.
My 1" pex clamp rings came today that I bought on ebay.I picked up a few pex fittings today at Menards while I was in town.I don't remember if I told you guys or not but my heat exchanger for my furnace came the other day.
Looks like a real nice piece.I still have it in the box.I will have to get a pic of it tomorrow for you guys.
Anyways here is a few more update pics.....

 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on December 07, 2010, 11:06:57 PM
Man it was a long day today.even though I didn't get started till after 3pm on the boiler.I did fix my mom's fireplace and a bad breaker in her panel box.
So I finally got out to the shop after picking the kids up after school.I managed to get all the lower door built,and installed.Now I have to show you my little secret i have been holding out on you guys.
I don't think you are going to see any other store bought outdoor wood boilers with built in gas chamber sight  glass! >:D
Well You will have to just check out the pics here ,and in the next post to see it all mounted.
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on December 07, 2010, 11:10:33 PM
 >:D
 :thumbup:
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Title: Re: Gasification wood boiler build
Post by: bikeralan on December 08, 2010, 12:49:32 AM
Cool! I used to work in a foundry and was in the melting dept. The cupolo that melted the iron had things called tweirs (sp?) that forced air in, they were very similar to what you have.
Will be neat to watch all your hard work gassifying and keeping your home warm.
Good work!
Title: Re: Gasification wood boiler build
Post by: jackel440 on December 09, 2010, 09:51:58 PM
Ok here is a shot of the bypass rod going through just the packing gland assembly I made to thread onto the pipe the rod will go in.I don't have the other end screwed on so you could see the rope seal i filled the large pipe coupling with to seal the rod and tube with.
Then I decided to put new seal on the bypass door ,and also show you the ramp that the bypass rod pushes on to get the door to open the hieght I wanted.
Then you can see in the 3rd pic the door is back in ,and I have the rope seal for the top cover in place so I can bolt the cover in place.
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on December 09, 2010, 10:02:08 PM
Here is a shot of the bypass rod's tube welded into the box.
Then we have a pic of the exhaust stack put into place and held up with my temporary brace.It totally sucks trying to hold a 36' long piece of shedule 40 pipe over top your head by yourself. :bash:
Then I tacked the top and bottom.Used my plumb bob to check the distance from the centerline of the base to the side of the pipe.  plus 3 5/16" to make sure my stack was running straight out the back.
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on December 09, 2010, 10:09:42 PM
Now I will shoe you my overflow pipe.I didn't want this thing puking on the roof.So I taped into the water guage stack,and then ran a drain line ove the side,then down ,and exit out the not used fork pocket.
Then I hung the panel box up,and started running my conduit and wires.I started terminating my wires to my controllers and relay.This crap is what takes so long.Coming along nicely though.
 :pic:

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Title: Re: Gasification wood boiler build
Post by: macmgfd on December 09, 2010, 10:24:47 PM
Looks great. What end of your push rod pipe are you putting the packing on? I am curious because that is something I can't get planned out for mine. I like how the rear of the boiler is laid out with your controls and draft blower real neat and organized. Great job keep it up. :thumbup:
Title: Re: Gasification wood boiler build
Post by: jackel440 on December 09, 2010, 10:33:51 PM
here is a quick video of the bypass in action.
gassification wood boiler bypass door (http://www.youtube.com/watch?v=Oc5GUBsF_Ac#)
Title: Re: Gasification wood boiler build
Post by: jackel440 on December 09, 2010, 10:38:44 PM
Looks great. What end of your push rod pipe are you putting the packing on? I am curious because that is something I can't get planned out for mine. I like how the rear of the boiler is laid out with your controls and draft blower real neat and organized. Great job keep it up. :thumbup:
This is a 1 1/4" pipe coupler that is reduced down to 1/2" pipe on one end.It is inside the bypass box.I didn't want any crud making it's way back down the tub to the fron of the stove.
On the outer end of the couple(the end were you see the rope seal hanging out)I again used 2 reducers(but the last one was a 1"to 3/8" recuder I drilled out to a little over a half inch so I would have a nice smooth hole for the rod to ride through,and not threads to gall up the shaft.
Title: Re: Gasification wood boiler build
Post by: quik_vw on December 10, 2010, 06:14:30 PM
Looking good,
I really like the sight glass, I know you will post a vid of the burn when the time comes.  This isn't your typical OWB, it is clear you have put much thought and planning into this project.  It's nice to see a project as it progresses, and especially when it's in the home stretch.  We are expecting single digit temp's here in sw mich. early next week, I know it's got to be getting cold there as well.  I bought 5 cord of firewood last week, that should take me through till spring.  I haven't been able to work on my project this week as other things have taken priority.
I have however ordered another round of parts, and will be able to get some time on it tomorrow.
Title: Re: Gasification wood boiler build
Post by: jackel440 on December 10, 2010, 10:55:21 PM
Looking good,
I really like the sight glass, I know you will post a vid of the burn when the time comes.  This isn't your typical OWB, it is clear you have put much thought and planning into this project.  It's nice to see a project as it progresses, and especially when it's in the home stretch.  We are expecting single digit temp's here in sw mich. early next week, I know it's got to be getting cold there as well.  I bought 5 cord of firewood last week, that should take me through till spring.  I haven't been able to work on my project this week as other things have taken priority.
I have however ordered another round of parts, and will be able to get some time on it tomorrow.
Yeah i have really put alot of thought into different things on it,and thanks for the compliments.
Today was like a heat wave here.I ran to my buddy's shop ,and picked up the 1" plate steel that will be the bottom of the burn chamber.He also gave me the B-deck steel to put in the bottom of my base to seal up the bottom and put insulation under the bottom of the tank.Then he gave me some tan metal sheets to use for my roof,and the  screws to put it on.Then he also gave me what was left of a roll of 1" pex to use under my house.
Me and my son(who just turned 11) were under the house all evening running that stuff and insulating it.We are both wore out after doing that all evening.
Yeah the weather is supposed to go to the crapper on moday.I was hoping to have it done by sunday,but I am not sure.I ordered my pumps ,and some y strainers from Natures Comfort through my friend who is a dealer.They were supposed to be here 2 weeks ago when I went and got my pipe.They supposedly shipped them wednesday.I still don't have them,so it might not matter if i am done sunday or not.
I got a pic of the kids decorating our tree after i helped them put on the lights and garland.

 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on December 11, 2010, 02:51:25 PM
Ok I am coming in to warm up,and dry out.I was cutting that plate for the bottom of the burn chamber,and it started to rain.Still trying to rain,but the temp is dropping again.I got the B-deck in the bottom of the frame,and then the end cap put on.
I then fabbed the throttle plates and adjusting handles for the air box.I tried to put some primer on the front of the tank,and the doors.I hope it will dry fairly soon.I have an electric heater blowing on the front of it.
Oh ,and I made a video I will post up of me cutting the plate.(In the Dang Rain! :bash:)
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on December 11, 2010, 02:59:04 PM
Here is the pic of the throttle blades to control the air flow to the burn chamber and the gas chamber.Then we got a pic of the rest of the b-deck installed ,and the end cap on.
And just for fun I threw in  apic of my poor 72' Charger sitting out in the weather. :-\
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on December 11, 2010, 04:40:59 PM
Shout out to my friends here!
torch cutting 1" plate Part1 (http://www.youtube.com/watch?v=lwBlIpdwYyo#)
part 1
Title: Re: Gasification wood boiler build
Post by: jackel440 on December 11, 2010, 04:41:43 PM
part 2
Torching 1" plate part 2 (http://www.youtube.com/watch?v=5Jrhzh2j_oU#)
Title: Re: Gasification wood boiler build
Post by: jackel440 on December 11, 2010, 11:37:26 PM
Well I took advantage of the warm temps,and got some more done.Not near as much that I wanted to.I got some of the frame work made to hold the metal siding.This thing is going to be huge by the time I get done with it!
After a long day of working on this thing I so wanted to call it quits.I trudged on to take advantage of the still what you could call warm temps.(The shop was staying above 40 with out the salamander).
I went back to the plates for the burn chamber.I cut the slots for the gas chamber ,and got all the plates installed.
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on December 11, 2010, 11:40:25 PM
Here is a few pics of the framing for the outside skin. :thumbup:
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on December 12, 2010, 04:36:55 PM
Not much progress today.I spent part of the day helping my mom,and then I fired up the skidloader ,and dug out my snowplow blade.So I am ready for the "BIG" snowstorm that we are supposed to get.LOL!
I did manage to get the metal for the outside of the boiler brought down to the shop from the stable.We had my son's birthday party this evening,so there is no point going out and trying to get much done now.I will just have to hit it tomorrow :thumbup:
Title: Re: Gasification wood boiler build
Post by: jackel440 on December 13, 2010, 06:25:58 PM
Well I drug up today ,and didn't do diddly squat. ::)
My pumps and plate exchanger never showed up.I just got a call from my buddy who ordered them from Natures Comfort for me.Them numb skulls (after not having them in stock for me 2 pick up 3 weeks ago when I got my pipe like they said they did)Sent the plate exchanger to his Millwright shop in Wabash then when he got home the pumps were at the end of his driveway out in the country. :bash:
This is after calling them and giving them my address on the phone and them repeating it back to me.
I mean Galveston is over 30 miles away from Wabash.Not even close.I could understand if the delivery guy left them at the wrong house on my road.No they sent it to 2 different places,and didn't even use my address...UGH! I mean it's only 16 degrees out and I need those parts so I can finnish my boiler!Now I have to drive 30 some miles to get my stuff that I paid to have shipped to me.What a bunch of crap.I can ship a horse across the country in a few days,but they can't ship a few items 120 miles away in less than a week. >:(
They have nice boilers ,but they need to get thier act together on the parts end.
Sorry for that ,but I have to vent a little.I needed these parts so I could continue on part of this build.I hate being at the mercy of other people.Dang it.
"hey honey fire up the kerosene heater ,it's going to be awhile on the boiler!"
Oh and Merry Christmas everyone. ;)
Title: Re: Gasification wood boiler build
Post by: jackel440 on December 16, 2010, 07:18:25 PM
A little update for you guys.I "volunteered" to work for my buddy's shop on wednesday,and picked up my pumps and plate exchanger that was delivered there.I then go sick and have been fighting a fever and congestion all day.
I have to work for my buddy tomorrow,and I am going to bend up a back door for the boiler while I am there.
later everyone
Title: Re: Gasification wood boiler build
Post by: bikeralan on December 17, 2010, 02:47:37 AM
Hang in there and keep healthy!.
With the added stress of the upcoming holidays and racing to get your stove online you are burning both ends.
My wife has major health problems with her feet and we have been cramming Dr appts in trying to beat the deductible from starting over, so I have ben a roadwarrior along with work as she can't drive.
We took one night last week and went to a motel 20 miles away and just sat in hot tub and relaxed.
So don't forget to goof off a little and recharge lol.
Happy holidays to your family!, speech over, now get that damn stove online ha ha.
Title: Re: Gasification wood boiler build
Post by: jackel440 on December 18, 2010, 01:36:04 PM
Thanks for the well wishes Bikeralan! :thumbup:
I pray that your wifes health improves.I can understand trying to get all you can in before the end of the year.
I have thought about sneeking away for a night like that ,but with no income at the moment that's not going to happen. I hear through the grapevine that I might be going back on monday though.
I got my door bent up last night before I left my buddy's shop.I also got a pic of the plate exchanger and pumps.
Then there is a pic of structural steel I just got painted ,and loaded on my trailer for my buddy at his shop.It is for a job at BF Goodrich in Marion,IN.My buddy's trailer wasn't long enough and he couldn't find a new trailer around here like he wanted in time.So I let him use mine.

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Title: Re: Gasification wood boiler build
Post by: oldchenowth on December 21, 2010, 02:24:19 PM
Gotta say man, very impressive!  Ambitious as hell too!  I wonder how many people, other than here, will actually appreciate all your work?  I've built race cars before and have not put in the time you are.  I hope you get to go back to work, your boss should appreciate your work ethic.  At least go back to catch your breath.
Title: Re: Gasification wood boiler build
Post by: jackel440 on December 21, 2010, 06:21:31 PM
Gotta say man, very impressive!  Ambitious as hell too!  I wonder how many people, other than here, will actually appreciate all your work?  I've built race cars before and have not put in the time you are.  I hope you get to go back to work, your boss should appreciate your work ethic.  At least go back to catch your breath.
Thanks for the compliments.I have a lot of time in it,and it is taking shape.I haven't been able to get much done here lately with being sick and all.Out of funds for a few things I need.I did go back to work this week so that is a blessing. :D
Just sucks that it's going to be another week or so before I get a pay check.I know you guys like what I have been accomplishing here.I wish you could see the thing that the couple of guys I work with build and fab at work all the time.I admitt I work with some guys who have real talent.
I know most people who have seen it here are in awe of it,but don't have a clue what it took to get to this point.That's fine,I know what is in the details.The guys who know what it takes can appreciate all the little things.
I am my own worse critic.I see things that are not how I wanted them to be,and it drives me nuts.Most others don't even have a clue there is anything not just"right". ;D
I was taking the tracks off my skidloader so I could plow snow tonight,and POW! the wrench slipped off the bolt and hit me right below the eye. :bash:Thank goodness it was cold out as my face was cold and it didn't bleed to bad. ::) So now my cheek hurts and has got my teeth hurting also >:(
Just can't win sometimes. :-\
I know I got to get this boiler done and up to heat soon.I want to be able to join the rest of you guys with fires in your stoves. :thumbup:
Title: Re: Gasification wood boiler build
Post by: jackel440 on December 22, 2010, 08:22:11 PM
Back door is hung finally.I also managed to favricate the end rafters to set the roof pitch.I then welded in the girt tubes in the front wall for the wall steel to screw to.Doesn't seem like alot got done,but I had to figure out all the rafter angles ,and then square up the frame so the outside isn't leaning.
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on December 26, 2010, 05:32:05 PM
Made a few mounts to hold a switch box,and a light box in the gable for a work light.I welded in a nipple on the front for a water temp guage.I then bent some conduit to run wires to the front 3 way switch.I got one of the purlins for the roof installed before I quit for dinner.
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on December 27, 2010, 05:00:36 PM
Nothing exciting to report tonight.I did manage to instal the rest of the purlins on the roof.I then did some terminating of wires,and hooking things up in the panel box.All the little details really seem to be slowing things down.Things are getting done though. :thumbup:
Title: Re: Gasification wood boiler build
Post by: John D on December 28, 2010, 05:21:09 PM
Great work! I just went thru all 9 pages....you sure do nice work...Id kill to have your garage......I cant wiat to see how it turns out and performs....only thing in your whole setup Im not liking is your pex tubing.....I hope the ground your putting it in is dry......and high above the water table....and you should be fine.
Title: Re: Gasification wood boiler build
Post by: tulenutn2o on December 28, 2010, 05:52:37 PM
Great work! I just went thru all 9 pages....you sure do nice work...Id kill to have your garage......I cant wiat to see how it turns out and performs....only thing in your whole setup Im not liking is your pex tubing.....I hope the ground your putting it in is dry......and high above the water table....and you should be fine.

I don't understand the dislike of PEX.
Title: Re: Gasification wood boiler build
Post by: jackel440 on December 28, 2010, 06:13:14 PM
Great work! I just went thru all 9 pages....you sure do nice work...Id kill to have your garage......I cant wiat to see how it turns out and performs....only thing in your whole setup Im not liking is your pex tubing.....I hope the ground your putting it in is dry......and high above the water table....and you should be fine.
Thanks for taking the time to look through the progress of my boiler.I didn't want to use this style of pipe either,but due to finances and time this was what I could come up with for now.This is actually just laying on the ground for for this year.It won't get buried until late spring.This tile is actually thicker than the standard pipe you would get at menards or lowes.

I don't understand the dislike of PEX.
It's not the PEX he dislikes it is the Pex in what looks to be water tile pipe.
Thanks for taking the time to look through the pages of my project.
Title: Re: Gasification wood boiler build
Post by: jackel440 on December 28, 2010, 06:21:50 PM
Well I spent another night mounting a box and more conduit for the stack light I will have on the stove.cut down my pipe for the light ,and came up with an adjustable mount for it.Ran seal tite down to the panel box for the wires.Spent the rest of the night terminating more wires.It is amazing how complicated this wiring is for all the different things I am doing with it.I will have to get a shot of the inside of the panel when it is all done.
And as always here is a few pics of progress......
 :pic:

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Title: Re: Gasification wood boiler build
Post by: bikeralan on December 29, 2010, 03:24:53 AM
Lookin good! devil is in the details, you are doing an excellent job!
Back to work yet?
Title: Re: Gasification wood boiler build
Post by: jackel440 on December 29, 2010, 03:33:24 AM
yeap back ,to work.Leaving right now.Heard ,we might be off for 2 more weeks again here soon.catch ya guys later tonight :thumbup:
Title: Re: Gasification wood boiler build
Post by: jackel440 on December 29, 2010, 06:18:11 PM
I had a productive evening tonight.I managed to design and build a defelector to help smoothly turn the burnt gases from the upper tunnels to the lower tunnels.I had to align a tube to match the sight glass pipe on the door.I then welded up the pieces and then insulated with K-wool.I also just tacked the back on so If for some reason I need to reinsulate in the future I can pop the back off.
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on December 29, 2010, 06:21:35 PM
Here is a shot of the deflector installed behind the door.I think this should really help get the exhuast gasses to flow nicely through the furnace. :thumbup:
 :pic:
Title: Re: Gasification wood boiler build
Post by: jackel440 on December 30, 2010, 07:28:41 PM
Got to love Indiana.Had a nice little earthquake this morning.Wife txts me about it ,and I said what are you talking about.LOL I was running a crane today and didnt even feel it. :o
Anyways I got the rear deflector made and insulated then installed it.Then I put a handle on it so it would be easy to remove so I can clean the lower chambers.
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on December 30, 2010, 07:33:36 PM
Here we have the rear deflector installed.Then a shot of the rope seal on the frame,and then the rear door installed.
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on December 30, 2010, 07:43:10 PM
Next we moved onto getting the fron twall steel installed.Well atleast the first piece anyways.I placed some fiberglass insulation inbetween the steel girts.
I got all the holes layed out ,and then cut them out with my Metabo slicer.After doing some fine tuning with it I then screwed it onto the frame.
After the sheet was on I started putting the doors back on.I threw a shot of the rtv in the slot before I put in the rope seal in the door channels.
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on December 30, 2010, 07:47:56 PM
And finally her is a pic of the door with the rope seal installed.Fit was excellent.
Last but not least is a shot of the doors on ,and the temp guage back on.
Hopefully tomorrow I can finnish the 2 air tubes inside the burn chamber ,and then work on the rest of the wall steel. :thumbup:
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on January 01, 2011, 04:24:45 PM
Ok managed to get the airtube fore the wood chamber fabricated.I then made a bracket so it can be easily removed for any reason,and also lock it in to place.
Then I started on the gas chamber air tube.I made an inverted "Y" to help make the flow of air in the back chamber go to each side.Instead of the air just going straight down and then hitting the bottom fire brick.
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on January 01, 2011, 04:35:37 PM
First pic is of the lower part of the tube going through the steel floor and into the gas chamber.It shows the air divertor in the end of the pipe.
Then the second and third pic is of the upper end of the tube were I made an adapter to go into the air tube coming from the air box.
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on January 01, 2011, 07:38:58 PM
Alright I finnished up the gas chamber air tube.Got all the pieces together and then welded up.I know I am sick and tired of climbing in and out of that dang burn chamber! :bash:
I then climbed in one last time ,and welded a stud in the back to hold the tube in tight.Came out real nice! :thumbup:
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on January 01, 2011, 07:42:16 PM
I got the bottom all insulated,and then started hanging insulation on the top and sides. :thumbup:
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on January 01, 2011, 07:48:57 PM
Here is another shot of some of the insulation going on.I will be putting more up on top than what I have shown here.
Then I included a pic of the stainless steel hanger I made to put my plate exchanger on.So It will not be hanging on the pipes or just on some crummy shelf of some sort.Got to have something nice :thumbup:
 :pic:

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Title: Re: Gasification wood boiler build
Post by: rtimber on January 01, 2011, 08:28:08 PM
 If the current Federal EPA gets its way...   mass storage- batch burning is one method to meet future EPA Particulate Matter emissions...  when current popular units are "smoldering" that is when most of the particulate matter is emitted.   By batch burning... P.M. can be lowered.   I think EPA's Phase 2 is .32...  WoodMaster has recently attained the Phase 2 rating with the EPA with .04....  way below the Phase 2 requirement...  so there is chatter that the EPA may eventually now lower the P.M. emissions allowed... >:(
Luckily, with a changing of the guard in Washington, some of the wind may be taken out of EPA's sails (EPA currently has more power than ever in history) and this whole requirement will be delayed (probably will not go away though)  ...  check out the EPA website, it is scary...   It is extremely expensive for any company to make it through the EPA testing....

Current units purchased are suppose to be "grandfathered"...  at least those that meet the individual State's requirements (ex. U.L. listed, etc.)

Also,  when making your own or buying a home-made unit... note that many insurance companies will not insure the unit OR any damages caused by the unit (sparks) that is NOT U.L. Listed....    Just fyi..   
Title: Re: Gasification wood boiler build
Post by: jackel440 on January 01, 2011, 11:19:05 PM
If the current Federal EPA gets its way...   mass storage- batch burning is one method to meet future EPA Particulate Matter emissions...  when current popular units are "smoldering" that is when most of the particulate matter is emitted.   By batch burning... P.M. can be lowered.   I think EPA's Phase 2 is .32...  WoodMaster has recently attained the Phase 2 rating with the EPA with .04....  way below the Phase 2 requirement...  so there is chatter that the EPA may eventually now lower the P.M. emissions allowed... >:(
Luckily, with a changing of the guard in Washington, some of the wind may be taken out of EPA's sails (EPA currently has more power than ever in history) and this whole requirement will be delayed (probably will not go away though)  ...  check out the EPA website, it is scary...   It is extremely expensive for any company to make it through the EPA testing....

Current units purchased are suppose to be "grandfathered"...  at least those that meet the individual State's requirements (ex. U.L. listed, etc.)

Also,  when making your own or buying a home-made unit... note that many insurance companies will not insure the unit OR any damages caused by the unit (sparks) that is NOT U.L. Listed....    Just fyi..

My state has no standards on these boilers.I am not concerned about how much particulate matter exits my stove.However it will be far less than most out there since it being a gasification unit.

Are you a Woodmaster dealer? ,Or tied to a furnace company?

I really don't see what any of this has to do with my unit.Except for the mass storage I plan to do in the future like I said in the beginning.
People build these all the time.Plus they build cars.etc .etc......
As far as insurance it is taken care of.
I think your statements maybe need to be in the General discussion thread,and not here.Do you have the information on the EPA requirments you are referring to?So others can see them ,and know what the Gov. has planned for all of us. :bash:
I hate to sound rude but "FYI" was noted before this project ever began.
 :thumbup:
 
Title: Re: Gasification wood boiler build
Post by: jackel440 on January 04, 2011, 07:09:19 PM
Well  anyways back to our regularly scheduled program. >:D
Everything is mostly all insulated.I managed to get the siding on the whole thing except for the very backside corners.thermocouple for the gas chamber is installed.
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on January 04, 2011, 07:16:26 PM
Here in the first pic is a shot of a poor mans sheet metal break :thumbup:
Works in a pinch.I didn't feel like running to the nieghbors to use his siding brake.
I got the roof steel on.Just have to get the ridge cap on for that part to be finnished for now.
 :pic:

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Title: Re: Gasification wood boiler build
Post by: mikenc on January 05, 2011, 10:11:34 AM
Haven't chimed in but have been watching progress. Lots of hard work but I am sure this will be a rewarding project for you. Anxious to here and see how it works!! Great looking job thus far.
Title: Re: Gasification wood boiler build
Post by: jackel440 on January 07, 2011, 08:31:46 PM
Haven't chimed in but have been watching progress. Lots of hard work but I am sure this will be a rewarding project for you. Anxious to here and see how it works!! Great looking job thus far.
Thanks for the good words. :thumbup:
Yeah I am getting anxious to drag it outside ,and put a fire in it.I just have tons of little things to wrap up that seems to take forever.It's all in the details I guess.
Hold onto your seat ,and we will be firing it up soon. :D
Title: Re: Gasification wood boiler build
Post by: jackel440 on January 07, 2011, 08:42:35 PM
Been busy with family stuff going on so I haven't been able to get much accomplished like I had hoped this week.I did manage to get some more wiring done,and then tonight I made some rat guard trim to go on the bottom of the wall steel.So the rats and mice can't climb in ,and tear stuff up.Caulked up the openings around the exhaust stack,front doors,light box,and switch box.Need to pick up a few more things in town tomorrow.Then hopefully get some more accomplished on it.I also got the ridge cap cut and placed on top of the roof.
Now you have to remember I am hand forming all my trim,as I don't have the funds to go buy new.As is the siding on my stove.It is used siding which came off an E.P.A. building about 10 yrs ago which was given to me in a stack.
 :pic:

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Title: Re: Gasification wood boiler build
Post by: tulenutn2o on January 08, 2011, 09:53:01 AM
You can be classified as a "green builder" then. I love recycling building materials. Nothing better, cheaper too. In today's world, new is  not necessarily better, and in alot of cases, inferior.
Title: Re: Gasification wood boiler build
Post by: jenkinswt on January 08, 2011, 05:57:22 PM
I just joined the site because I am interested in possibly building a owb but read through your entire post and anxious to see the results. You are doing a good job of putting your family first and keeping a balance between your job and this project which is alot of work. Keep up the good work.
Title: Re: Gasification wood boiler build
Post by: jackel440 on January 08, 2011, 10:26:33 PM
You can be classified as a "green builder" then. I love recycling building materials. Nothing better, cheaper too. In today's world, new is  not necessarily better, and in alot of cases, inferior.
LOL ,yeah youcould say that since the siding is green!
I ,agree some new products aren't as good as the old stuff.

Title: Re: Gasification wood boiler build
Post by: jackel440 on January 08, 2011, 10:32:29 PM
I just joined the site because I am interested in possibly building a owb but read through your entire post and anxious to see the results. You are doing a good job of putting your family first and keeping a balance between your job and this project which is alot of work. Keep up the good work.
This is a great site to find information.I am anxious to see it doneas much as all the peeps following along. :thumbup: I  would have it done by now if the temps would stay in the upper 20's or 30's. I took this weekend off as my wife and daughter went out of town, and me and my son stayed home.Ifigured I would get afire in it by sunday.It was so cold today that i didn't even bother working on it.So Me and my son went out to eat, and got a new game for the wii and played it.
Maybe tomorrow will be more productive. :thumbup:
Title: Re: Gasification wood boiler build
Post by: tulenutn2o on January 09, 2011, 11:20:44 AM
I just joined the site because I am interested in possibly building a owb but read through your entire post and anxious to see the results. You are doing a good job of putting your family first and keeping a balance between your job and this project which is alot of work. Keep up the good work.
This is a great site to find information.I am anxious to see it doneas much as all the peeps following along. :thumbup: I  would have it done by now if the temps would stay in the upper 20's or 30's. I took this weekend off as my wife and daughter went out of town, and me and my son stayed home.Ifigured I would get afire in it by sunday.It was so cold today that i didn't even bother working on it.So Me and my son went out to eat, and got a new game for the wii and played it.
Maybe tomorrow will be more productive. :thumbup:
I call that "buddy" time.  :thumbup:
Title: Re: Gasification wood boiler build
Post by: dhibbs75 on January 09, 2011, 06:19:58 PM
Kool Build..... Ive read all the post today.......  Ive been looking for some pipe to build me one.......  Have you been keeping up with the amount of HOURS/DAYS you have in it.......    Post wise has been since Oct 1..... :post:
Title: Re: Gasification wood boiler build
Post by: jackel440 on January 09, 2011, 06:45:08 PM
Kool Build..... Ive read all the post today.......  Ive been looking for some pipe to build me one.......  Have you been keeping up with the amount of HOURS/DAYS you have in it.......    Post wise has been since Oct 1..... :post:
I was keeping track,but then I got side tracked with other stuff.I usually worked on it 4hours at a time,between doing other stuff at the farm aslo.I had a few weeks where there was other things goingon so nothing got done.Now we have had some bitter cold, and there is no point in freezing to death in the shop.If its in the upper 20's I can get the shop to warm up with the salamander.If its in the teens it won't warm up.(and thats a waste of kerosene at $3.49).I have lost more time dut to that than anything here lately.
I have about 4 or 5 hours of more stuff to do to it, and then it should be ready to pull out of the shop. :thumbup:
Title: Re: Gasification wood boiler build
Post by: Bull on January 09, 2011, 09:18:39 PM
Awesome job Jackel, I would love to see it in operation sometime.
Title: Re: Gasification wood boiler build
Post by: dhibbs75 on January 10, 2011, 07:38:11 PM
Is the owb going to be psi or open.....
Title: Re: Gasification wood boiler build
Post by: jackel440 on January 10, 2011, 07:44:28 PM
Is the owb going to be psi or open.....
open system
Title: Re: Gasification wood boiler build
Post by: jackel440 on January 10, 2011, 07:57:53 PM
Well i hurried home and beat it out to the shop so i could try to get something accomplished today after work.I got alot of loose ends taken care of.I spent most of the evening fiinishing up wiring and hooking up an inside light for the back of the furnace in the"control room".LOL
I got the stack indicator light all hooked and assembled.Then hooked up the thermocouple wires to the controllers.I am no electrician, but I managed to get everything terminated fairly cleanly.
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on January 10, 2011, 08:07:50 PM
I finnished seal the ridge cap the roof steel.Then I mounted the front light.I also have a shot of my stack light.Each light has different meanings,and i can see them from the house.That way i know whats going on without going outside.
Blue- power is on to the boiler
green -controler turned on damper and blower
red-- Low water level in tank
clear- ready to load.When you flip the front switch it turns on the front light plus the clear stack light,while interupting power to the relay for the blower/damper
orange-not used yet
 :pic:

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Title: Re: Gasification wood boiler build
Post by: dhibbs75 on January 10, 2011, 08:17:34 PM
Clear is just to help shed light for night time use???  or do you have some temp setting to let you know that the fire is low and its feeding time...
Title: Re: Gasification wood boiler build
Post by: jackel440 on January 10, 2011, 08:32:37 PM
No it won't put out that much light.That's what the front light is for.It is just to indidcate that the blower power is interupted.
Say my son or wife goes out to load it,and then come back to the house.I can tell them to go back out and flip the switch back on. >:D
Title: Re: Gasification wood boiler build
Post by: bikeralan on January 11, 2011, 01:19:45 AM
Super idea for the operation lights ! great job, the blue hairs up here would be stopping and going with your lights lol.
Glad you are closing in on getting it operating, has been fun almost being there with you.
Thanks for all the pics, good luck!!!
Title: Re: Gasification wood boiler build
Post by: dhibbs75 on January 11, 2011, 05:03:37 PM
That sounds like a good Family proof light.... ;D

While brain storming today looking in grainger and msc for the fan, stat and relay, coil.....  I had a BRAIN FART and wondered what was your back up plan when power goes out....  On your intake door you have a servo opening and closing the door....  If power goes out for a while your flame will get rolling and may boil over.....Do you have a bat backup to close the draft door when power fails??????

Im going to go with a magnetic coil  energized to open loose power shuts air off.........
Title: Re: Gasification wood boiler build
Post by: jackel440 on January 11, 2011, 07:10:33 PM
That sounds like a good Family proof light.... ;D

While brain storming today looking in grainger and msc for the fan, stat and relay, coil.....  I had a BRAIN FART and wondered what was your back up plan when power goes out....  On your intake door you have a servo opening and closing the door....  If power goes out for a while your flame will get rolling and may boil over.....Do you have a bat backup to close the draft door when power fails??????

Im going to go with a magnetic coil  energized to open loose power shuts air off.........

Already a step ahead of ya. ;)The damper actuater is only power to open.It is spring return to close.So if there is a power outage it will shut automatically.
If you go back and watch the video of it in operation.It sounds like it is running when it closes, but actually it is the spring inside the unit returning it to the close position.I pulled the wire out of the socket so it would close.Only has power to open, and hold it open.They are designed just for this kind of application.To close a damper when poer goes out.
Those Belimo dampers are high quality pieces.I lucked out and found mine on ebay for a good price.Took like 4 trys to get one.
The way these operate is why I wanted one to use on my air box. :thumbup:
Title: Re: Gasification wood boiler build
Post by: dhibbs75 on January 11, 2011, 07:36:32 PM
Thats what I was wondering...  Thanks for the info...  I was looking at grainger for soleniods and did not find excatly what I wanted..   Dont really like the cheap ones....  could rust and stick.....  What model is yours....   If you go to AS and look at the thread apples to apples owb.   Youll see my post what im going to build....  Waiting on a quote for the metal and having it bent.   I think im going to have my fire box with water all around except the front..  most eff.....   I post a better pic on there latter....  still in ruff draft....   You post has been alot of help for me...   When I start mine I will try and post like you did........    good luck on yours....
Title: Re: Gasification wood boiler build
Post by: jackel440 on January 12, 2011, 07:30:59 PM
Well I had a very productive night in the shop :D
Well after I replowed the drive as it drifted shut anyways.I took a piece of steel siding and ripped it to the width I needed to hand form the corners of the back of the housing.
I first hemmed the edges and then bent it 90 degrees.I put up some pics of part of the process so If someone had to do this they would have an idea of what to do.I then put butyl tape that was left over from a duct work job I did,on ,the corners of the furnace to seal it all up.
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on January 12, 2011, 07:34:58 PM
Here is another shot of the tape.Same stuff they use on rv windows and a/c units.Then there is a shot of the back all completed. :thumbup:
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on January 12, 2011, 07:44:11 PM
Ok now we're getting to the good stuff.I managed to throw power to it yesterday.I had a direct ground in one circuit.As soon as the controller cycled the relay it would blow the breaker.So tonight I had to figure out where I messed up on my wiring.
Ended up being just 2 wires that I terninated wrong.after about 15 minutes of trouble shooting everything is working like planned. :D
I took a pic so you can see the controlers powered up,and then a shot of my exsplosion proof light I mounted inside the "control room"  :P
I also swapped out 2 of the ball valves I had on the bottom of the furnace,and replaced them with to flange ball valve assemblys.I then wired up my pumps ,and mounted them on the piping. :thumbup:
 :pic:

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Title: Re: Gasification wood boiler build
Post by: jackel440 on January 12, 2011, 08:01:51 PM
Well it won't let me load any more pics.I guess we have come to the end of the road maybe :'(
I had some cool pics of the controller and light stack to share.I will try again later I guess.
Thanks for watch'n so far :thumbup:
Title: Re: Gasification wood boiler build
Post by: bikeralan on January 13, 2011, 01:44:57 AM
Ok now dig the wood out of the snow and let er rip!!
Great build, tanks for all the pics along the way. Good luck!!!
Title: Re: Gasification wood boiler build
Post by: Airgap on January 13, 2011, 11:26:45 AM
Nice work Jackel...Control panel looks really neat and well done. Entire build looks great. You should pat yourself on the back , and show it to everyone you know.

Is this the first OWB you've built?
Title: Re: Gasification wood boiler build
Post by: jackel440 on January 13, 2011, 12:45:09 PM
Thanks for the compliments guys. :thumbup:
I ,am going to have to definately dig the wood out of the snow.
Yes this is the first OWB I have built.I don't know if I will build another anytime soon or not. :o
I asked PhinPhan about not being able to load any more pics, and he said he modified the file size.So I will try to add the one that didn't get loaded last night.
Title: Re: Gasification wood boiler build
Post by: jackel440 on January 13, 2011, 12:46:49 PM
Ok here is a close up pic of the controllers powered up.
The top controller is showing the temp inside the water tank at 34 degrees.Now the top controller is what actually controls the furnace.
The lower controller is showing the temp of the gasification chamber at 35 degrees.This controller does nothing but just show the temp in the gas chamber.
The red light on the panel actually has a label on it but the bright light drowns out the lettering.
Then we come to the stack light picture.
The clear light tells us the front switch is in the "load" position,and it is safe to open the door and put in wood.The red light is indicating that the furnace needs water put in it. 8)
I'm sorry but I think this light deal is cool as heck!
A couple more loose ends to wrap up and then it will be time to drag her out side.Then put a fire inside of her. :thumbup:


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Title: Re: Gasification wood boiler build
Post by: Dirtslinger on January 13, 2011, 04:05:34 PM
The lights are cool  :thumbup:  I put a small led light on the outdside of mine so I can tell from the house that the blower is on. I only like to fill the stove if the blower is on less smoke I have to eat when I open the door.
Title: Re: Gasification wood boiler build
Post by: mikenc on January 13, 2011, 04:35:34 PM

Lots of hard work but the rewards will be worth it. Neat light to.
Title: Re: Gasification wood boiler build
Post by: jackel440 on January 16, 2011, 02:11:07 PM
Made a short video tutorial of how the controls and such work on my gasifier.Thought I would share it with you guys so you would understand what all I have going on with it.
Catch ya later
Operation of the gasification boiler controls (http://www.youtube.com/watch?v=6wVo0XcGE8k#)
Title: Re: Gasification wood boiler build
Post by: jenkinswt on January 16, 2011, 06:12:59 PM
Looking pretty good.
Title: Re: Gasification wood boiler build
Post by: jackel440 on January 17, 2011, 07:24:03 PM
Well I have the boiler setup outside behind the shop,and she is burning real nice.lit her off at 7:20 and at 9:00 she has went from 42 degree water to 140 degree water.she is gasifying in the lower chamber.waiting on her to make it to 180 before I head to bed.wife made a video of me moving her out of the shop.I am on my phone right now so I will post from the computer later.
Title: Re: Gasification wood boiler build
Post by: bikeralan on January 18, 2011, 02:14:37 AM
woo hoo!!!!
Title: Re: Gasification wood boiler build
Post by: jackel440 on January 19, 2011, 07:00:15 PM
My House is freaking HOT inside now!!!!! WOOO HOOOOO!!!!!!!!!!!!!!!!
I had some major things happen the last couple days.The night I got the boiler fired up which was monday.I didn't have it hooked up to the house yet.So I went to bed ,and my wife relit the kerosene heater.Well when I woke up at 4:40am to get ready to goto work.My house was filled with a haze!I thought the house was being filled with smoke from thew boiler.But it didn't smell like wood smoke.The damn kerosene heater was burning just one side,and filled my house with smoke and soot.My smoke detector battery was dead,so it didn't go off.The wife and I opened the windows and started airing the house out.Got the kids up and took them to my moms house.We all had black soot in our noses.This could have been a life threatening situation.We are very lucky.So I left work early and came back home ,and busted my rear to get heat in the house.I worked nonstop from 11 am till 12:30amthat night.I had everything working except that I couldn't get the damn fittings to stop leaking on the heat exchanger in my furnace.
I accepted defeat last night and went to bed with just the electric heaters running.Bought new fittings today and resoldered the heat xchanger ,and got everything working.
Wife has been busting her tail trying to get the house cleaned up from all the soot.We are going to have to repaint the walls as it is a mess in here now.
Well we have free heat now and it is a nice feeeling to know We can be as warm as we want.
I am sitting in my pajamas,eating ice cream,drinking a coke while the house is above 80* while watching some WWII film footage ;D
My son went to let the dog out to go potty.I told him "you can stand there with the door open as long as you want,just throw an extra log in the boiler!"hahaha! >:D
I LOVE IT!!!!!

Title: Re: Gasification wood boiler build
Post by: yoderheating on January 19, 2011, 08:36:24 PM
 That is a wonderful feeling to have! A friend and I were talking about this very thing just this evening. We come home from work and our wives have the house just roasting hot and we don't even care. Freedom from heating bills! Glad you have yours up and running.
Title: Re: Gasification wood boiler build
Post by: jenkinswt on January 19, 2011, 08:50:09 PM
Man this isn't even my stove and I am excited hearing your story. Glad everyone is warm and healthy. When your warm because of your own work its a good feeling. Especially when there is such a difference in temperature from outside to inside, makes you appreciate it alot.
Title: Re: Gasification wood boiler build
Post by: Scott7m on January 19, 2011, 09:32:43 PM
Glad to hear that your stove is performing as you had hoped! 

What was the problem with the leaky fittings on the exchanger?
Title: Re: Gasification wood boiler build
Post by: bikeralan on January 20, 2011, 02:44:03 AM
Glad you got the boiler on line!! As a kid my dad used a big fuel oil space heater and it clogged up 3 or 4 times filling the whole house with soot.
Fast forward a few decades my job was a truck driver delivering powerline poles, it had a loader on top of the truck and when the wind would get just right the exhaust would get you, same smell as that damn heater, it would make me barf lol, so I know your plight it is a terrible smell.
Now you can insulate your garage and have a huge man cave!
Great job! all we need now are a few pics of the boiler in action!
Title: Re: Gasification wood boiler build
Post by: jackel440 on January 20, 2011, 08:01:09 PM
Thanks for all the well wishes guys.was definitely a scary moment the other morning.did give the wife an exscuse to repaint the whole dang house.we went color shopping after work.I did get a few pics tonight before it got dark on me.plus shot a video of it running for you guys.I just got it started to upload.said it had 140 minutes Togo.lol!so maybe it will be loaded by tomorrow. Going to be real busy for the next few days.so I will get the pics loaded sometime.
on my heat exchanger I couldn't get the dangcopper fitting to seal up when isweated them on.I had them off 3 times recleaned and flux. But no dice.broke down and got a Mapp gas torch and new fittings.soldered up fine then.the heat exchanger was just sucking to much heat from the joint to make a good joint.catch ya guys later.
Title: Re: Gasification wood boiler build
Post by: jackel440 on January 21, 2011, 03:31:57 AM
Here is a quick video of the boiler up and running for you guys to check out. :thumbup: Gasification OWB fired up and running (http://www.youtube.com/watch?v=sv15nglYX60#)
Title: Re: Gasification wood boiler build
Post by: willieG on January 21, 2011, 05:08:32 AM
Very fine looking job! Your finished product is impressive and the craftmanship is number 1. You have not just made a OWB you have made a work of art!

I am however, still not a fan of your underground line. I had it, it failed after three years for me. It worked fine until (i think what happened) a small stone or something worked it's way through the outer tile and let water in. Once water got in there the inuslation value of the wrapping went to about 0 and you could see the trench in the middle of winter. no snow and soft ground.

Again, your stove looks and runs great in your video! I hope your pipe lasts for you better than it did me.
I am not sure how much a non perferated second  tile large enough to put your underground line in may cost, but it may be worth it to try and keep moisture away from your lines or in the worst case scenerio you could retrieve the line you now have and pull through a new one in case of failure in the future. Or you can be like me and go through the whole "dig up the old one with the backhoe and start over again" routine

Wonderful video and happy burning!
Title: Re: Gasification wood boiler build
Post by: Scott7m on January 21, 2011, 07:24:07 AM
 :thumbup:
Title: Re: Gasification wood boiler build
Post by: lawrencep on January 21, 2011, 08:31:07 AM
that is awsome its always great to see a long hard project pay off great job.
Title: Re: Gasification wood boiler build
Post by: koutsman on January 21, 2011, 08:41:46 AM
Great job!!!   I can tell your son sure is proud of his daddy!!!   Now you and your family can sit back and relax and enjoy the heat (especially today). Oh yea but not till after the house is repainted. Right???   Again, Great job!!!
Title: Re: Gasification wood boiler build
Post by: Jbuck on January 21, 2011, 12:23:02 PM
Ok jackel440, now that you have it up and running I am concerned you will become bored, so in an effort to help you out, if you will send me a materials list I'll load up my trailer and head your way and you can build me one just like it LOL.  All kidding aside I am very impressed with your fabrication skill, while I can weld well enough to keep my old farm equipment patched together I have never been good at designing and fabrication.  Off subject, was that an old Plymouth I saw in your shop in one of the photos of the build? If so and considering the 440 in your user name I would bet your a Mo-Par guy.  Enjoy that boy, while I,m 6'3'' and 260 lbs. I have to lookl up to mine now and he can't even think about fitting into my coveralls anymore.  Once again congrats on the completion.
Title: Re: Gasification wood boiler build
Post by: jackel440 on January 21, 2011, 12:38:30 PM
there is nothing but Mopar on this property  >:D
Title: Re: Gasification wood boiler build
Post by: jackel440 on January 21, 2011, 01:44:28 PM
Ok jackel440, now that you have it up and running I am concerned you will become bored, so in an effort to help you out, if you will send me a materials list I'll load up my trailer and head your way and you can build me one just like it LOL.  All kidding aside I am very impressed with your fabrication skill, while I can weld well enough to keep my old farm equipment patched together I have never been good at designing and fabrication.  Off subject, was that an old Plymouth I saw in your shop in one of the photos of the build? If so and considering the 440 in your user name I would bet your a Mo-Par guy.  Enjoy that boy, while I,m 6'3'' and 260 lbs. I have to lookl up to mine now and he can't even think about fitting into my coveralls anymore.  Once again congrats on the completion.

Well I appreciate your concern for my boredom. ;)I want you to rest assured I have already started to brainstorm a little on a nice log splitter for my operation here. ;D
As far as a material list I have a stack of half burned up prints that I made somewhere in the shop that you could try to decipher.LOL!
You could probably buy 2 new ones for what I would have to charge you labor for one.LOL Plus I don't think you would like the 5 month lead time. :bash:
I thank you for the compliments on my fabbing.I am by no means the best ,but I do a decent job that I am not afraid to take to the fair.I do fabrication at work everyday.I am a millwright by trade so I love what I do.
Yeah my son warmed my heart yesterday.He told me that he is writing a paper in school about his 3 favorite things and I am one of them.Next to the Wii and his nerf gun,but (not in a particular order). ^-^
Yeah I am a mopar man.I love the fact I get to work at Chrysler and then play with them at home.
Now there is 2 cars sitting in the shop.A 68' Coronet 440 ,but I believe you are talking about the white one.
That is a 1960 Desoto Fireflite with a 361 and the push button automatic.
Thanks again for following along.Now there is going to be some more pics and another video to come so come back and check in.
Title: Re: Gasification wood boiler build
Post by: tulenutn2o on January 21, 2011, 03:08:47 PM
Hey Jackel, I will spare you building a stove  just like that one................ I will however come get yours as I notice it is already on wheels for me.LOL!!!Great job and make sure you get that shop heated for next year.
Title: Re: Gasification wood boiler build
Post by: jenkinswt on January 21, 2011, 10:23:29 PM
Nice video Jackel. This has been a awesome write up and I believe if someone was wanting to build this they could get alot of their information off this thread.
Title: Re: Gasification wood boiler build
Post by: jackel440 on January 25, 2011, 06:58:07 PM
Ok here is the video of me moving it out of the shop.Thought maybe you guys might like seeing how I did it.My wife made a bunch of short videos and I had to splice them together so that's why it is choppy.Anyways her you go ;)
LPK-440 leaving shop.wmv (http://www.youtube.com/watch?v=xsR5xU9YyaE#)
Title: update on how she is running
Post by: jackel440 on January 25, 2011, 07:13:25 PM
Ok we have been up and running for a week now,and I have to say I am quite exstatic about how it is working!We have gotten a 24 hour burn from her .Our temps were in the teens last night and in the mid 20's today.I loaded her full yesterday at around 5:30-6:00 pm.Son and I went out to her today at around 5:45pm to see what we had left in the firebox.I had about 3 or four pieces mostly burned up.So we loaded her back up ,and shut the door.Turned on the blower and the controller kicked on.We let it light up for a little bit.I then decided to open the blast gate to see what kind of flame i might see in the gas chamber.The window was lit up like I was looking at the sun!
Never had that intense of a fire in the gas chamber yet.I could see the gas burning coming through the floor slots ,but not flame filling up the entire burn tunnel until tonight.I came to the conclusion with my son that the firebrick has finally dried and cured.The refractory was glowing.
I checked the guage for the thermocouple in the gas chamber and it made it almost to 1300*!!! before the controller shut down the furnace as the water temp had came to the set point.
I made a video of what we had witnessed tonight.You can see the flame shooting out of the hole in the front baffle when we open the door.I have not had that happen until today.I have gotten heat out of there and had ash fly out ,but never flame!I have to say it was quite impressive to see it really maxing out during the gasification burn.I have to say I am one proud pappa!LMAO! >:D
Gasification chamber burn and temperature (http://www.youtube.com/watch?v=cpTBizlhpKU#)
Title: Re: Gasification wood boiler build
Post by: tulenutn2o on January 25, 2011, 07:26:34 PM
Awesome! I know when I have let fire go out and refired the unit. that it takes awhile to get full gasification, I supppose because the brick needs to build up heat.
Title: update
Post by: jackel440 on January 29, 2011, 06:46:40 PM
Well I thought I would let you guys know how things are going.Can we say "Freaking Great!!!!!"man I LOVE THIS THING! >:D >:D >:D
I have been getting 24 hr burns on one full load.I have been loading it at around 6pm ,and then loading again at 6 the next day.Temps have been in the 20'lows in the teens right now.Had a few people stop by and check her out.Everyone seems quite impressed with it.
Man I love having a smoke scented jacket,and a warm house! :thumbup:
Title: Re: Gasification wood boiler build
Post by: bikeralan on January 30, 2011, 03:47:10 AM
I am glad it is performing at or above your expectations. Has to feel good that you built it!
Title: Re: Gasification wood boiler build
Post by: jackel440 on January 30, 2011, 07:27:26 AM
I am glad it is performing at or above your expectations. Has to feel good that you built it!
Yes it feels real good to know I built it ,and what I made is heating my home and keeping my family warm.
Title: Re: Gasification wood boiler build
Post by: jackel440 on February 03, 2011, 03:20:06 PM
Well I had a critical part failure today.Got home from work ,and the water was down to 110*.the fire was out and I had 3 partial logs in the stove.So i reloaded the stove had the bypass open,and finally got the wood to relight.turned the blower on and everything seemed to be working but the stove wasn't taking off like it should.So i thought the gas chamber was plugged so I raked out the passages.Still no good air flow.I then thought perhaps my air feed pipe in the burn chamber was plugged up with creosote.Cleaned the tube off.Still didn't seem to be getting much air flow.Opened up the back of the stove,and sure enough my damper actuator seems to have died.I manually opened my damper and turned the blower back on.She is running like a champ again.So I have a new damper on order and I hope it is here by saturday.
I did buy this at an idustrial surplus house so I don't know for sure of it's condition.It looked to be new,but who knows.I had about $40 in it so I am not sweating it too much.I will just have to wait untill the new gets here and install it.
Title: Re: Gasification wood boiler build
Post by: jackel440 on February 03, 2011, 05:33:39 PM
Well the actuater wasnt bad after all.I guess I will have a back up on the shelf now. :o
Looks like the fire went out since the wife didnt load it while i was at work.We are down in the single digits.So while it was on and calling for heat the actuator must have an internal safety so it only stays open for so long under power.After I had the stove up to temp and was idling the power was off to the actuator,and I believe an internal safety reset.I went back out and turned on the blower in manual mode.Then damper worked like normal. :thumbup:
So i buttoned it back up and reloaded her with some more wood.Good to go again! >:D
Title: Re: Gasification wood boiler build,update
Post by: jackel440 on February 17, 2011, 05:18:33 PM
Still running strong!24 hr burn times.Not burning too much wood.Real happy with the gasification process.I suggest to anyone looking at this style stove to go with it.Warmed up here and all the snow is turning into water i am getting flooded by the fields and turning into a mud hole!I am sure it will get cold again though.later everyone :thumbup:
Title: Re: Gasification wood boiler build
Post by: Smakman on February 20, 2011, 12:48:23 AM
If you were to build another, would you do anything different the second time?  Oh......and will you build me one?  LOL.
Title: Re: Gasification wood boiler build
Post by: tulenutn2o on February 21, 2011, 06:28:05 AM
If you were to build another, would you do anything different the second time?  Oh......and will you build me one?  LOL.
I asked him to build me one first. He told me to bring the steel, byob, and him some too. Jackel, you may have a new business venture here!
Title: Re: Gasification wood boiler build
Post by: jackel440 on February 21, 2011, 07:38:26 PM
If you were to build another, would you do anything different the second time?  Oh......and will you build me one?  LOL.
I asked him to build me one first. He told me to bring the steel, byob, and him some too. Jackel, you may have a new business venture here!
;D I dont think so!LMAO
I wouldn't mind helping someone build another one as long as its not on my dime. >:D
I actually enjoyed building mine,and I just wish I had a big sheet metal shear and 8' finger break to do 1/4".If I did I would make a few just for kicks.
Now as far as changing anything.A few minor things yes.I would place my thermocouple tube in a different spot in the tunnel chamber.I might make my slots in the floor going into the gas chamber smaller.I might make a plate to drop in part of the slot to play with a theory I have there.
Other than that not too much else to change.The main thing is making a high efficiancy log splitter to keep up with the wood splitting part >:D
Title: Re: Gasification wood boiler build
Post by: Smakman on February 22, 2011, 06:53:42 AM
Ok......so what does a big sheet metal shear and 8' finger break cost?  :)
Title: Re: Gasification wood boiler build
Post by: jackel440 on February 22, 2011, 07:56:50 AM
TOO MUCH! lmao!
But If you want to donate them to my cause. I am more than willing to build yours then >:D
Title: Re: Gasification wood boiler build
Post by: tulenutn2o on February 22, 2011, 05:57:30 PM
If you were to build another, would you do anything different the second time?  Oh......and will you build me one?  LOL.
I asked him to build me one first. He told me to bring the steel, byob, and him some too. Jackel, you may have a new business venture here!
;D I dont think so!LMAO
I wouldn't mind helping someone build another one as long as its not on my dime. >:D
I actually enjoyed building mine,and I just wish I had a big sheet metal shear and 8' finger break to do 1/4".If I did I would make a few just for kicks.
Now as far as changing anything.A few minor things yes.I would place my thermocouple tube in a different spot in the tunnel chamber.I might make my slots in the floor going into the gas chamber smaller.I might make a plate to drop in part of the slot to play with a theory I have there.
Other than that not too much else to change.The main thing is making a high efficiancy log splitter to keep up with the wood splitting part >:D
Are you saying high efficiency, as in less work for you? If so I have developed the perfect hi-efficiency log splitter.....................I built it myself with help from the wife.................We call him our son! ;D He cut my splitting time in half! Input costs can be somewhat high though. I might be paying more in the long run........... :o
Title: Re: Gasification wood boiler build
Post by: jackel440 on February 23, 2011, 02:09:25 PM
If you were to build another, would you do anything different the second time?  Oh......and will you build me one?  LOL.
I asked him to build me one first. He told me to bring the steel, byob, and him some too. Jackel, you may have a new business venture here!
;D I dont think so!LMAO
I wouldn't mind helping someone build another one as long as its not on my dime. >:D
I actually enjoyed building mine,and I just wish I had a big sheet metal shear and 8' finger break to do 1/4".If I did I would make a few just for kicks.
Now as far as changing anything.A few minor things yes.I would place my thermocouple tube in a different spot in the tunnel chamber.I might make my slots in the floor going into the gas chamber smaller.I might make a plate to drop in part of the slot to play with a theory I have there.
Other than that not too much else to change.The main thing is making a high efficiancy log splitter to keep up with the wood splitting part >:D
Are you saying high efficiency, as in less work for you? If so I have developed the perfect hi-efficiency log splitter.....................I built it myself with help from the wife.................We call him our son! ;D He cut my splitting time in half! Input costs can be somewhat high though. I might be paying more in the long run........... :o
;D ;D ;D
I have one of those homemade log splitters also!I think you are correct on the payoff not being there right now!LMAO.Oh well mine is only 10 yrs old ,and just got his first shot at running the splitter i borrowed a week ago.He did a good job of it.He also had to show my wife how to use the winch I put on the truck to pull my mom and her truck out of a snow bank while I was at work.He made sure she didn't let the cable pile up on one side of the drum. :thumbup:I am proud of him.
Title: Re: Gasification wood boiler build
Post by: tulenutn2o on February 23, 2011, 05:56:21 PM
If you were to build another, would you do anything different the second time?  Oh......and will you build me one?  LOL.
I asked him to build me one first. He told me to bring the steel, byob, and him some too. Jackel, you may have a new business venture here!
;D I dont think so!LMAO
I wouldn't mind helping someone build another one as long as its not on my dime. >:D
I actually enjoyed building mine,and I just wish I had a big sheet metal shear and 8' finger break to do 1/4".If I did I would make a few just for kicks.
Now as far as changing anything.A few minor things yes.I would place my thermocouple tube in a different spot in the tunnel chamber.I might make my slots in the floor going into the gas chamber smaller.I might make a plate to drop in part of the slot to play with a theory I have there.
Other than that not too much else to change.The main thing is making a high efficiancy log splitter to keep up with the wood splitting part >:D
Are you saying high efficiency, as in less work for you? If so I have developed the perfect hi-efficiency log splitter.....................I built it myself with help from the wife.................We call him our son! ;D He cut my splitting time in half! Input costs can be somewhat high though. I might be paying more in the long run........... :o
;D ;D ;D
I have one of those homemade log splitters also!I think you are correct on the payoff not being there right now!LMAO.Oh well mine is only 10 yrs old ,and just got his first shot at running the splitter i borrowed a week ago.He did a good job of it.He also had to show my wife how to use the winch I put on the truck to pull my mom and her truck out of a snow bank while I was at work.He made sure she didn't let the cable pile up on one side of the drum. :thumbup:I am proud of him.
Mine is 12 going on 18, I think. Shot up 4-5" this year, strong as an ox. Poor ole dad may have to watch what he says pretty soon.LOL!! He's got his mother's temper. Me, I am the calm one. Really, I am, I promise.
Title: Re: Gasification wood boiler build
Post by: jackel440 on February 26, 2011, 06:38:42 AM
tulenutn2o
 you better watch out.He might shove you in the furnace!LOL!
Title: Re: Gasification wood boiler build
Post by: tulenutn2o on February 26, 2011, 09:10:42 AM
Never thought of that! I'll be watching what I say for sure.
Title: Re: Gasification wood boiler build
Post by: dhibbs75 on March 05, 2011, 08:15:04 AM
In all your research is it better to have the back wall of the fire box in water or dry??      I got a good price on 1/4 steel yesterday Ive got to finish designing my owb..  Im not building a gasification unit.....I found 1/4 4x8 for 190 and 1/4 4x10 for 230 a sheet..... not bad about 1/2 price of anybody else and they wil break it also.....Off to the drawing board...well paper.......
Title: Re: Gasification wood boiler build
Post by: jackel440 on March 05, 2011, 09:35:02 AM
The more water you have surrounding the burn box the more btus you will be using to heat the water.no point in having the back not covered with water.just losing heat if not.
Title: Re: Gasification wood boiler build
Post by: martyinmi on March 06, 2011, 05:14:59 AM
Mornin' Jackel. I was up till after midnight last night reading all your posts and watching the video's. I'll jump on the bandwagon and let you know cool it is that you built your own boiler, especially with the help of your kids and encouragement of your wife. Awesome job! This morning I got up and went way back in the threads and tried to figure out how as best I could how many cubic feet of wood your new baby holds. Looks like it's somewhere between 12 and about 16. I've got a little Empyre Pro Series 100 and it holds about 5 cu. ft. I've got to load it twice a day, sometimes three times, but a face cord still lasts me on average more than 2 weeks. I like everything about it, I just wish my firebox was as big as yours. Once again, awesome job! When my new fab gets out of the prototype stage, I'll have my little brother show me how to post pictures and show ya'll some of my ideas on a gasifier. (My little brother is 6'3'' and 220 and 41 years old- and infinately more wise than me when it comes to electronics).
   Take care,
   Marty
Title: Re: Gasification wood boiler build
Post by: cab on March 06, 2011, 07:53:17 AM
Im not building a gasification unit.....

I think you will regret that greatly....
Title: Re: Gasification wood boiler build
Post by: jackel440 on March 07, 2011, 05:39:21 PM
Mornin' Jackel. I was up till after midnight last night reading all your posts and watching the video's. I'll jump on the bandwagon and let you know cool it is that you built your own boiler, especially with the help of your kids and encouragement of your wife. Awesome job! This morning I got up and went way back in the threads and tried to figure out how as best I could how many cubic feet of wood your new baby holds. Looks like it's somewhere between 12 and about 16. I've got a little Empyre Pro Series 100 and it holds about 5 cu. ft. I've got to load it twice a day, sometimes three times, but a face cord still lasts me on average more than 2 weeks. I like everything about it, I just wish my firebox was as big as yours. Once again, awesome job! When my new fab gets out of the prototype stage, I'll have my little brother show me how to post pictures and show ya'll some of my ideas on a gasifier. (My little brother is 6'3'' and 220 and 41 years old- and infinately more wise than me when it comes to electronics).
   Take care,
   Marty
Thanks for the compliments!I tried to involve my family were I could.I am glad you got to enjoy and maybe get some ideas from my project.That's why I tried to post alot of pics and share my ideas.
I had a paper with a figure on what the capacity of the firebox was ,but I think it may have burned up on the fab bench at some point in time. ;D
I never got my wood stacked in a good organized fashion so i could get a good feel for how much I was burning.I know it is just sipping the wood.
I used 3 skid loader buckets of wood per week when the temps were down into the single digits.Thats is a 66" low pro bucket and then I split and stacked the rounds that were in the bucket.Now with the temps in the mid 30's to lows in the teens I have been burning a pile stacked on 1 and 1/2 wood pallets about 3' high and that is lasting me for a week.24 hr burns the whole time.
The first thing I would change if I was building from scratch again I would build the door taller.Mine is currently 20"x20" and I would like to see it a little bit taller and wider also.
I look forward to pics of your gasifier.good luck to you on it. :thumbup:
Title: Re: Gasification wood boiler build
Post by: truecountry on March 07, 2011, 08:19:22 PM
how did you do math on water in boiler .... you got a nise ass stove and i see u planned it well.. great job
Title: Re: Gasification wood boiler build
Post by: jackel440 on March 08, 2011, 03:03:02 PM
how did you do math on water in boiler .... you got a nise ass stove and i see u planned it well.. great job
I just took a little time and did alot of math.I figured out the volume of the firebox,and lower gas chamber.Then I found the area for the 6 heat exchanger pipes.I also took into account the fire box opening .Then I subtracted that from the fixed dimension of my water tank.Had to be a little creative due to the angles of the burn chamber ,but all in all it was easy. :thumbup:
Title: Re: Gasification wood boiler build
Post by: martyinmi on March 08, 2011, 03:38:02 PM
Did you ever get a chance to measure your exhaust gas temperature? My goal with mine will be around 250 f. under full gasification. If my metal gets bent and my pipe truck shows up before this weekend I should be able to start welding Sat. morning.
   Marty
Title: Re: Gasification wood boiler build
Post by: Smakman on March 08, 2011, 07:40:42 PM
I wish you had a copy of all the measurements and materials and such.  I would be willing to pay for that!
Title: Re: Gasification wood boiler build
Post by: jackel440 on March 08, 2011, 07:47:01 PM
I wish you had a copy of all the measurements and materials and such.  I would be willing to pay for that!
i Had a cut list and prints made up by me.The problem was that I ended up modifying those pieces .So then  it all was custom fit as I went.
Title: Re: Gasification wood boiler build
Post by: vpd66 on March 22, 2011, 11:42:58 AM
Hey Jackel440,
   Where did you find the info to calculate some of the dimensions of your gasification boiler. I'd like to crunch some numbers on a boiler for my heating needs. Some of the info I'd like to calculate would be firebox size, nozzle size, heat excahanger size, how long of a burn and how much wood to raise the temp of "x" amount of water, and etc. There must be some info on this that isn't to far over everyones head.
Title: Re: Gasification wood boiler build
Post by: jackel440 on March 22, 2011, 05:39:35 PM
Hey Jackel440,
   Where did you find the info to calculate some of the dimensions of your gasification boiler. I'd like to crunch some numbers on a boiler for my heating needs. Some of the info I'd like to calculate would be firebox size, nozzle size, heat excahanger size, how long of a burn and how much wood to raise the temp of "x" amount of water, and etc. There must be some info on this that isn't to far over everyones head.
There are charts online that you can get the info on the BTU output per each type of wood burnt.I know Willie G. has them or knows where they are at online.I based my firebox size on the other stoves on the market.I just tried to get the most out of my materials.
There is alot of information online about gasification ,theory and design.I would say your best bet is to just start researching all you can find out.The best way to learn is going to be by trial and error.
Now there is no reason to rengineer what has been done by other companys.Study other manufacturers designs and learn from them.They spent the money on R&D might as well learn from it.
Title: Re: Gasification wood boiler build
Post by: dhibbs75 on March 22, 2011, 08:11:32 PM
I have a ?? about gasification...   This is just a thought....  Would extending the smoke stack pipe down into the ash box work as a gasifer?? Making the ex have to go down throught the fire....  Still brain storming...
Title: Re: Gasification wood boiler build
Post by: jackel440 on March 30, 2011, 09:00:58 AM
I have a ?? about gasification...   This is just a thought....  Would extending the smoke stack pipe down into the ash box work as a gasifer?? Making the ex have to go down throught the fire....  Still brain storming...
you would get. Some burning of the smoke,the issue is you need to introduce air to the secondary burn to get it to burn clean.plus you need to be able tohave the chamber be able to withstand the high temps.so even if you did lower the stack its not going to be a true gasifier.
Title: Re: Gasification wood boiler build
Post by: martyinmi on March 30, 2011, 05:02:22 PM
You can get the smoke to burn, but the hard part is recovering some of the gasified heat.I actually introduced super heated air into my old burner just behind the baffle(not water cooled) and I could easily get it to burn the smoke,and my wood consumption went down a bit, but it drove me nuts not being able to recover that extra heat. My stack temps were always in the 800- 1000* range. Although they've never complained, I'm sure my neighbors were very happy when that conversion took place.
Title: Re: Gasification wood boiler build
Post by: Ridgekid on April 27, 2011, 09:27:48 AM
I too enjoyed this post and videos. Very impressive. Thanks for sharing.
Title: Re: Gasification wood boiler build
Post by: jackel440 on April 27, 2011, 11:37:15 AM
I too enjoyed this post and videos. Very impressive. Thanks for sharing.
thanks. I wanted to share it with everyone here.
Title: Re: Gasification wood boiler build
Post by: outback on May 09, 2011, 01:05:39 PM
first let me say looks like A-1 usa work to me. did you keep records of all material bought so you know the total cost of the unit. just wondering how much you save by building your own. less the consumables like gas and air, welding wire etc. . on welding, did you weld both sides of everything or seal one side and stitch the other?? did you use a 80 grade welding wire or a 70 series wire? not sure with that much heat exposure. i would like to build one myself, but i don't know if i have the smarts. very capable of the welding and burning, but the planning is the tough part for me. are you selling a blue print to follow with detailed drawing? the pics you have are great but to me they would be hard to follow. the brain doesn't work as it should so i need pics with numbers. please let me know if something is available. one thing about building your own you get to know how the system works, at least i hope anyway. i can see theres a lot of questions so i'll stop for now.
Title: Re: Gasification wood boiler build
Post by: jackel440 on May 09, 2011, 06:05:16 PM
first let me say looks like A-1 usa work to me. did you keep records of all material bought so you know the total cost of the unit. just wondering how much you save by building your own. less the consumables like gas and air, welding wire etc. . on welding, did you weld both sides of everything or seal one side and stitch the other?? did you use a 80 grade welding wire or a 70 series wire? not sure with that much heat exposure. i would like to build one myself, but i don't know if i have the smarts. very capable of the welding and burning, but the planning is the tough part for me. are you selling a blue print to follow with detailed drawing? the pics you have are great but to me they would be hard to follow. the brain doesn't work as it should so i need pics with numbers. please let me know if something is available. one thing about building your own you get to know how the system works, at least i hope anyway. i can see theres a lot of questions so i'll stop for now.
Thanks for the compliments! :thumbup:
I don't have an exact price tally as I got some special deals on my materials.Plus online buys and ebay can be your friend.I do figure I am about 1/4 to a 1/3 of the price of an comparable new manufactured unit. ;D
The burn chamber and gasification chamber and heat exchanger tubes are welded on both sides.The outer tank is welded on both  sides except for the front if i remember correctly.LOL
Everything is welded with 70 series wire.I used approximatly one spool on the whole thing.I did weld some fittings with alloy rod.couple of spots were done with some 7018.
I made my own blue prints but they got modified as I went.Engineering changes on the fly. :o
I did like being able to incorporate my own ideas or improve upon others that are out on the market.I am was able to design and make it easier to be serviced in case of a problem.Being a Millwright I like to plan ahead for when I have to repair things.
My advice to you is if you want to build it go for it.Take your time and do LOTS of research on whats out there and how well each design works.Decide on what you think works and what doesn't work.incorporate your own designs in your build.Make lots of drawings of each part and lay it out and see how each part will affect other aspects of the furnace.
much easier to keep redrawing parts on paper than to rework steel after fabbing something to find out it wont work.
If you have ? just holler and I will help if I can. :thumbup:
Title: Re: Gasification wood boiler build
Post by: jackel440 on May 09, 2011, 06:16:08 PM
The smallest Turbo Burn unit is 1349 gallons.  They are all over the US and Canada.  The bigger the tank the more you can heat....etc...pool, greenhouse, shop.  The Turbo burn has been around since the 80's.  Small family owned business.  www.turboburn.net (http://www.turboburn.net)
Seems to me you must be either the owner or a saleman as you have posted this thing on other threads.Your site doesnt give much information other than how much water it holds and a small blower.No information on what kind of materials its made of or firebox size.Looks kind of neat but the cartoon video leaves much to be desired on what it is.I imagine it costs more than I would pay,and I dont believe the claim of it heating all that water on one burn to temp and last for 5 days? ::)
good luk with it :-\
Title: Re: Gasification wood boiler build
Post by: RSI on May 10, 2011, 05:02:43 PM
maybe that's because of it being a smaller company??
That is no excuse for a lousy website. It would have been easier to make a decent website than that useless video.
Can you post some pictures of yours? Probably start a new post about it instead of hijacking this one.
Title: Re: Gasification wood boiler build
Post by: Ridgekid on May 10, 2011, 05:26:25 PM
Better yet ask our moderator to open a forum for your product instead of spamming everyone elses.
Title: Re: Gasification wood boiler build
Post by: jackel440 on May 11, 2011, 06:55:09 PM
maybe that's because of it being a smaller company??
That is no excuse for a lousy website. It would have been easier to make a decent website than that useless video.
Can you post some pictures of yours? Probably start a new post about it instead of hijacking this one.
RSI, Ridgekid  my first thought was what does this have to do with this build thread,and the whole point is to not burn oil,gas and such? ???
I was more concerned about the same dang post and link on other threads.I say to you Mr. TurboBurn that you should post about your stove in the general section.I have not ever heard of your company,but I wouldn't mind seeing more details and pics of the stove in your own thread. :thumbup:
I also burn one fire a day and can heat my home for 2 days  on one burn when it is not fridged out.Plus I only have 440 gal. of water.the website lists over 1K gals. on thier stove so I think in my opinion ,I know which one perhaps might be a little more efficient.
Sounds like you love your stove and I am glad you do.It's all about saving yourself money.good luck to you.
And now back to the originally scheduled thread. ;D
Title: Re: Gasification wood boiler build
Post by: jackel440 on May 11, 2011, 07:43:39 PM
I do have a late tid bit of info to post on my gasifier.
The stove seemed to be choking on air flow to the burn chamber.I was getting plenty of air flow to the gas chamber.I thought perhaps I had to much of a coal bed in the burn chamber,as I was having issues with the nozzles pluging with ash on the left side.
I was opening the lower chamber door and pulling any fine ash out.The tunnels seemed to be filling up more than they should as I definately was having an air pressure issue.
The stove was having a hard time coming back to temp after I let it set and the water temp would get to 140*.I would have to open the bypass door and let it burn that way.I figured there was an issue with the air manifold being plugged with creosote.AS I have been burning alot of green wood till now.
So I got a few warm days and shoveled out all the ash in the burn chamber,cleaned all the tunnels in the gas chamber out.I then pulled out the air manifold to check it.Boy did I have some issues with the holes being plugged with creosote. :bash:
I knew when I was making it that it might be a problem in the future.I plasma cut the holes about 1" to 1 1/4" DIA. I think when I made it.
So I took back to the shop and opened up the holes on just the bottom side of the tube.Mainly to help direct the air flow downward toward the coal bed and improve combustion.I didn't get pics of the modified holes hopefully I can get those this summer.
I reinstalled the modified air manifold.Reloaded the furnace up,and lit her off with my special fire starting compound >:D
I have to say now that she is really breathing good now.I haven't had any issues with the gas nozzle plugging with ash.The burn chamber is burning much more complete.I now have my wood load turning to charcoal like it should as the wood burns.I guess now I shall wait untill nxt fall to see how this improvement shall work.
Unless I hook this baby upto the hot tub I might be getting soon ;D
Title: Re: Gasification wood boiler build
Post by: Ridgekid on May 11, 2011, 08:27:00 PM
lit her off with my special fire starting compound  >:D

Newspaper Sticks and matches ..Right? Now thats funny I don't care who you are. Git-R-Done! LMAO
Title: Re: Gasification wood boiler build
Post by: jackel440 on May 12, 2011, 01:21:59 PM
lit her off with my special fire starting compound  >:D

Newspaper Sticks and matches ..Right? Now thats funny I don't care who you are. Git-R-Done! LMAO
Actually it is a jug of old oil,gas,desiel,tranny fluid,and kerosene mixed together in a couple of gallons jugs I use to start campfires and other fires >:D
Yeah there is a few sticks and some paper in there too. ;)
Title: Re: Gasification wood boiler build
Post by: Ridgekid on May 12, 2011, 01:33:39 PM
Unlike me, you don't have a warranty hanging over your head. Thats a no no with CB.

I feel like a Boy Scout when I have to light mine!
Title: Re: Gasification wood boiler build
Post by: RSI on May 12, 2011, 02:52:19 PM
Negative responses? I said I wanted to see pictures but that they should be a new post, not this one.
Title: Re: Gasification wood boiler build
Post by: jackel440 on May 12, 2011, 04:02:19 PM
Unlike me, you don't have a warranty hanging over your head. Thats a no no with CB.

I feel like a Boy Scout when I have to light mine!
LOL that's funny as I am a Scout leader. ;D
I tell you another great way to light these babys off when thier cold.My buddy does this on his NC Gt500 when he cleans it all out.He will put in his small wood on bottom like normal and then bigger stuff.He then has one of those weed burner torches that he lights and lays inside the burn chamber.He says after about 5 to 10 minutes depending on how wetr the wood is .She takes right off.I will be having my one of those next winter when I am in a hurry to clean her out and restart it. :D
Title: Re: Gasification wood boiler build
Post by: NewToIt on May 13, 2011, 08:13:59 AM
Jackel.... sorry for the hijack, but I can't stand it when people do this..... so here goes......


Turbo burn...... When you post comments like this in another thread....

"I know there is alot of information out there.  I recommend the Turbo Burn stored energy system.  They are a company out of Washington State where they have banned outdoor burning.  They have a website www.turboburn.net (http://www.turboburn.net).  They have different sized units so depending on what you need they start fairly small to huge (actually installed in cargo containers)  They are heating towns in Alaska!!!"

.....using the word "they", then later admit that you are the owner of the company in this thread.... it tends to look a little shady, IMO.  It bugs me when people are seemingly hiding their true identity/agenda.


Other than that, post away.  I would love to learn more about your product, but didn't get much from your website.


Good day,

Mark
 
Title: Re: Gasification wood boiler build
Post by: jackel440 on May 13, 2011, 08:40:13 PM
Wow love all the friendly peeps on here.....by the way it's Mrs Turbo burn.  I was actually responding to the comments about your stove holding 440 gallons (which is great if you're talking about a 440 Hemi) and thought I would say mine held 1349 gallons but apparently everyone got off track.  I love hearing about the build going on but not the negative responses I've gotten....wow!! I have only been on this site for a week and learning how it works.....so to everyone I apologize for not being able to navigate on the site as well as some.  From now on I'll just read and not post....good luck all.
Mrs Turbo Burn,
      Thanks for inquiring about the stove I built.Yes it does hold 440(I am a mopar man ;) ) gallons of water.Now it is GREAT as it holds more than most of the stoves on the market out there.I actually have plans to heat 2K gallons of storage water in the future like I had posted earler in my thread.
        I like your shot at trying to reference mopar engines,but a Hemi was never produced in a 440 cubic inch size.440 is a RB engine which is "Raised Block".which came with 2V,4V and the famous "six pack" induction.
       Now as far as your stove is considered.I think it is great the capacity it has,but your posting didn't come off like this one you posted.Me and like several others just felt it was a sales push.I think it was felt it didn't provide any benefit to this thread.
       Now I  apologize to you if I came off harsh sounding,as that was not my intention.I was trying to direct you to the general section where more people could see and talk about your furnace.Please start a thread on it and post pics like I asked before.I would like to see how its designed and work.Especially after the claims that have been made about it.
       You will find there is great "peeps" on here just have to introduce yourself.By placing links to your stove in several threads without much info pertaining to the thread it just comes off as spamming.Might not have been your intention but that was how it was percieved.
       I invite you to talk about my furnace in this thread all you would like.I then look forward to your own thread on your furnace so we all can learn about it.I know other members will want to know about it.so good luck to you. :thumbup:
Title: Re: Gasification wood boiler build
Post by: NewToIt on May 16, 2011, 11:09:10 AM
My apologies Turbo Burn..... I misread one of your posts.  It's no excuse, but I fully expected you to be the owner or affiliated with the company with the nature of some of your first posts..... then people started talking about "YOUR" website.....  I guess, in hindsight, I saw what I wanted to see and not what was really there!

Sorry again, and like I said earlier..... post away.  There is a lot of good and knowledgeable people here!

Mark
Title: Re: Gasification wood boiler build
Post by: paperman on September 25, 2011, 12:19:19 AM
.Then a shot showing where water can flow around the back of the heat exchnger trough and between the back tank wall.
 :pic:

Question on the 2nd pic on post #47.  I assume hot flue gas goes through the ID of the round flues, what is in contact with the OD of the tube?  I see a baffle seperating the waterspace and the tube? 

Any idea as to what you stack temps are leaving the unit?  Im building a material list and wondered if another pass would be worth the headache.  Thanks for the great build thread.  Nice to see people still build rather than buy. 
Title: Re: Gasification wood boiler build
Post by: jackel440 on September 25, 2011, 10:23:05 AM
.Then a shot showing where water can flow around the back of the heat exchnger trough and between the back tank wall.
 :pic:

Question on the 2nd pic on post #47.  I assume hot flue gas goes through the ID of the round flues, what is in contact with the OD of the tube?  I see a baffle seperating the waterspace and the tube? 

Any idea as to what you stack temps are leaving the unit?  Im building a material list and wondered if another pass would be worth the headache.  Thanks for the great build thread.  Nice to see people still build rather than buy.
Paperman,
  Welcome to the forum! :thumbup:
  Thanks for checking out my stove and yes I love to build rather than buy my stuff.
Now back to your question.Yes the burnt gases from the refractory chamber exit up through the I.D. of the 6 pipes.Now the purpose of the baffle surrounding the pipes.All the return water goes directly into the baffled chamber ,and then the water has to travel up around the heat tube helping to reheat  the water quicker.Then the water comes out of the baffle chamber 2" from the top of the water jacket to mix back with the rest of the water in the water jacket.
Now if you have any more questions just post them up.The whole purpose of my build was to show others what can be done.I would have liked to have done a few things different but she works good and I will be stoking her up soon with the way the dang weather is acting. :thumbup:
Title: Re: Gasification wood boiler build
Post by: paperman on September 25, 2011, 07:28:19 PM
Thanks for the quick answer.  I looked but just didnt see the outlet in the pics.  As you said you would change things, what might they be?  Waterbox material 1/8"?  Do you play much with the air mix valves for main air Vs. reburner air?  Can you give me rough dimentions on the gasifier tunnel.  I assume you made it to fit standard fire brink to avoid cutting or was it just a "bend up what looks good and try it" type? 

What keeps the fire alive during the smolder/non-heat cycle? I mean as far as air goes as it looks to be locked down pretty tight.  What are your thoughs on feeding air into the sides of the fire lower in the fire box as some commercial units.   Whats everybody thought on more passes for the flue gas.  P&M has I think 3 passes with very low EGT.  Seems the more tube the more heat pulled out.

I hate to point it out but I think a saw a, well lets just say, a brand X car in the yard in one of the youtube vids.  I bleed blue myself but my old man came right out of mother MOPAR.     
Title: Re: Gasification wood boiler build
Post by: jackel440 on September 26, 2011, 05:55:54 PM
Thanks for the quick answer.  I looked but just didnt see the outlet in the pics.  As you said you would change things, what might they be?  Waterbox material 1/8"?  Do you play much with the air mix valves for main air Vs. reburner air?  Can you give me rough dimentions on the gasifier tunnel.  I assume you made it to fit standard fire brink to avoid cutting or was it just a "bend up what looks good and try it" type?  I would have changed the air box where the blower mounts a little bit and perhaps used a bigger air feed tube,but the one I have installed works just fine.I have played with them a little bit ,but it was due to a air flow issue which turned out to be the holes in the air tube in the fire box plugging up from creosote the more i used it.I had to pull the tube out and open them up which fixed the problem.I did make the tunnel to fit standard hard brick.I forget the dimensions off the top of my head.If i remember tomorrow I will try and measure it.I still had to cut blocks to fit for air flow and the different chambers.

What keeps the fire alive during the smolder/non-heat cycle? I mean as far as air goes as it looks to be locked down pretty tight.  What are your thoughs on feeding air into the sides of the fire lower in the fire box as some commercial units.   Whats everybody thought on more passes for the flue gas.  P&M has I think 3 passes with very low EGT.  Seems the more tube the more heat pulled out.
Yes it is locked down tight.I haven't ever had an issue with the fire relighting.The burn chamber holds so many hot coals that it lights right up as soom as the oxygen is reintroduced.I almost put in another pass just like the P&M but I had comitted to my design ,and decided to not change again.I do really like how the PM are set up.If I build another in the future I would look real hard at doing something like that.I never did check my stack temp,but it is quit hot coming out.Your not gonna leave your hand in there.Yes your right the more linear feet of tube the more heat absorbed.
I hate to point it out but I think a saw a, well lets just say, a brand X car in the yard in one of the youtube vids.  I bleed blue myself but my old man came right out of mother MOPAR.   
Oh yeah that was my BNLaws crapmaro sitting out here.He finally sold it to a buddy and got it out of here.I still think it would have been fun to squish with the grapple bucket on the skid loader.I am a Mopar man.Ma mopar put the food on the table herealso.I love working for the company that makes my favorite cars and trucks.New and old.I am second generation here,and I am also skilled trades.I have too many old mopars ,and now I want to buy my uncles HD to play on :bash:
Title: Re: Gasification wood boiler build
Post by: tulenutn2o on September 26, 2011, 07:33:20 PM
Ouch! You are a mean man Jackel.Thalt shall cherish all american cars............ ;D
Title: Re: Gasification wood boiler build
Post by: paperman on September 27, 2011, 05:39:12 AM
Good to hear you cleansed the yard.  Its amazing how easy pure carbon/charcoal can stay lit or even catch fire.  I make maple syrup in the spring.  The pan I use was on an arch that did not burn so well.  The flues of the pan would build up with carbon.  While building a new arch for the pans I sprayed the bottom of it with sparks from a grinder.  Not heavy snag grinder sparks but light sparks from a 4” Metabo. I see smoke and figure I lit myself up again.  Nope the bottom of the pan had a light glowing ring.  The carbon was burning and was very hot.  Amazed me.  :o

Does your 1” plate sit on the brick or on the horizontal portion of the fire box ?  With your PID controller what  is your temp. differential set at and is a wider spread better?  I would guess you want the burn to be as long as possible as you are most efficient at full burn.  So would a 15-20 differential be better than the 5 I always seem to see?  It would bring the unit up to temp and dwell longer. 
Title: Re: Gasification wood boiler build
Post by: jackel440 on September 27, 2011, 07:42:10 AM
Ouch! You are a mean man Jackel.Thalt shall cherish all american cars............ ;D
nah I'm not mean just Moody.LOL! I brain washed my kids to love mopars and then they started calling everything junk.I then had to tell them Chevy's and fords were ok,but imports will .always be trash and not allowed in my drive. >:D
Title: Re: Gasification wood boiler build
Post by: jackel440 on September 27, 2011, 07:57:02 AM
Good to hear you cleansed the yard.  Its amazing how easy pure carbon/charcoal can stay lit or even catch fire.  I make maple syrup in the spring.  The pan I use was on an arch that did not burn so well.  The flues of the pan would build up with carbon.  While building a new arch for the pans I sprayed the bottom of it with sparks from a grinder.  Not heavy snag grinder sparks but light sparks from a 4” Metabo. I see smoke and figure I lit myself up again.  Nope the bottom of the pan had a light glowing ring.  The carbon was burning and was very hot.  Amazed me.  :o

Does your 1” plate sit on the brick or on the horizontal portion of the fire box ?  With your PID controller what  is your temp. differential set at and is a wider spread better?  I would guess you want the burn to be as long as possible as you are most efficient at full burn.  So would a 15-20 differential be better than the 5 I always seem to see?  It would bring the unit up to temp and dwell longer.
Got to love those Metabolism grinders! I don't know how many times I caught my shirt on fire with a slicer wheel.
Yes the 1" plate sits on the 1 1/4" lip that runs the length of the fire box.there is 1/4" sheet of high density k wool between the brick and plate also.
Ian currently running a 5* differential on my controler.I plan to play with it more this winter.I think it needs to short to keep the temp up in the brick but we shall see what happens.
Title: Re: Gasification wood boiler build
Post by: paperman on September 27, 2011, 09:20:45 AM
Do you see a benefit either way of using the two upper chambers flowing into 2 lower chambers like your stove opposed to the single hole and wrap around like the P&M?  The NC furnace is laid out like yours or yours like theirs, either way didn’t know if you knew of a reason each is laid out that way.  The one holer’ design looks good but its hard to beat a two holer’ when you have a bunch of gas to pass.  I’m leaning toward copying the P&M’s gas path but am still looking on what gasifier section to use. 

Waterbox thickness?  Do you think welded stays between the firebox and outer tank would be better than  the stiffeners you installed?
Title: Re: Gasification wood boiler build
Post by: jackel440 on September 27, 2011, 09:35:43 AM
I am undecided on the style of tunnels in the gas chamber.I have thought if my refractory dies and needs replaced I might try a single tunnel with a larger nozzle to see how it performs.would be alot easier to clean one single chamber than two.then again if that single exit plugs up your done.I have had on tunnel plug and the other keeps working.I credit That to my air flow problem and green wet wood.
my water tank does have welded stays to the fire box .there are four on each side.as Farl as thickness I am happy with 10 gauge. Plus the two runners under the gas chamber are welded to the bottom of the water tank.
Title: Re: Gasification wood boiler build
Post by: paperman on September 27, 2011, 11:41:17 AM
Working at a papermill I get most any kind of wood.  Not dry but not fresh cut either.  Been stacked in log form 2 months to year.  This wood is chipped on site for our use.  Could a gasifier but chips well or a waste of time?

 
Title: Re: Gasification wood boiler build
Post by: jackel440 on September 27, 2011, 01:34:24 PM
Working at a papermill I get most any kind of wood.  Not dry but not fresh cut either.  Been stacked in log form 2 months to year.  This wood is chipped on site for our use.  Could a gasifier but chips well or a waste of time?
They burn wood chips in them all the time.I have seen videos of sawdust being burned but I would think the burn times would be short with sawdust.the chips might burn up quicker than logs but I see no reason not to give it a try.if you have access at either I would be on it.I am curious to know what happens..how big. Are the chips? Are we talking mulch size?
Title: Re: Gasification wood boiler build
Post by: paperman on September 27, 2011, 05:21:07 PM
The chips are 4MM thick and approx. 1 1/2" wide.  We have "oversize" rejects that are anything bigger than 2" and undersize at 3/4".  Also our chipper has a metal detector that can find a nail in a 20" log.  It stops the belt and reject the 3-4 logs behind this one as well as the suspect log.  Cheap to toss $10 in pulpwood than $1800 in chipper knives.  It all equals free wood to the employees. 

Did you think of doing a castable refractory opposed to bricks?  You can mold it to what ever you want.  Kind of a clay like consistancy until its fired. 
Title: Re: Gasification wood boiler build
Post by: tulenutn2o on September 27, 2011, 06:36:21 PM
Hey Jackel, last year when tree man dumped here, he also left a small pile of chippings. Since I had to clean up any way, I got in the habit of throwing a scoop or 2 on top of logs when I burnt. Don't know if it helped or hindered, but got rid of chips and fire was hot.
Title: Re: Gasification wood boiler build
Post by: jackel440 on September 27, 2011, 07:56:40 PM
The chips are 4MM thick and approx. 1 1/2" wide.  We have "oversize" rejects that are anything bigger than 2" and undersize at 3/4".  Also our chipper has a metal detector that can find a nail in a 20" log.  It stops the belt and reject the 3-4 logs behind this one as well as the suspect log.  Cheap to toss $10 in pulpwood than $1800 in chipper knives.  It all equals free wood to the employees. 

Did you think of doing a castable refractory opposed to bricks?  You can mold it to what ever you want.  Kind of a clay like consistancy until its fired.
Sounds like the wood chips would be a good deal since theyre free! :thumbup:
If you got a place to store it I would take it.Even if you had to mix it with logs to get a longer burn ,but I bet it would work great.
I don't know if doing castable is worth the hassle.I passed on using it for the simple reason that what if?I needed to repair the brick in the middle of winter.I can use brick to fix a fracture.But if I had some special one off piece that would mean some down time.which I couldn't afford to deal with.
Title: Re: Gasification wood boiler build
Post by: jackel440 on September 27, 2011, 07:58:32 PM
Hey Jackel, last year when tree man dumped here, he also left a small pile of chippings. Since I had to clean up any way, I got in the habit of throwing a scoop or 2 on top of logs when I burnt. Don't know if it helped or hindered, but got rid of chips and fire was hot.
I would like to scoop up my debri from cutting and splitting and put in a bin of some sort to later use in the boiler.No point in letting it go to waste. :thumbup:
Title: Re: Gasification wood boiler build
Post by: paperman on September 29, 2011, 07:42:38 AM
Why is it the gas chambers are on the bottom?  Seems you are fighting the air and heat wanting to rise.  Must be a real reason as that seems to be the way it is done by most. 
Title: Re: Gasification wood boiler build
Post by: jackel440 on September 30, 2011, 04:46:54 PM
Why is it the gas chambers are on the bottom?  Seems you are fighting the air and heat wanting to rise.  Must be a real reason as that seems to be the way it is done by most.
updraft gasification is alot more involved and not practical for our applications.Much simpler to build a down draft unit.
Title: Re: Gasification wood boiler build
Post by: jackel440 on October 09, 2011, 06:23:41 PM
Well A little update for this new burning season.Last year I had an exstension cord ran out the door and around to the back of the shop to power the gasifier.Today i got an out side recepticle mounted and hooked up.Plugged the burner in ,and she came right to life. ;D
I drained all the 440 gallons of water out of her.Only got a little nasty sediment when it first started draining.all the rest came out nice and clear.
Now when I placed the unit last year it was cold and frozen out.I leveled it and was good to go.Well by athis spring and summer she had settled and my blocke were sinking.So I jacked her up and put some stone down and releveled it.
I am getting ready to hook up the shop feeder line up so there is heat in there this year.I am going to make a stainless steel plate to bring it through the wall.
The boiler is all cleaned out and pretty much ready to go.Should be filling it back up with water on wednesday. :thumbup:
Title: Re: Gasification wood boiler build
Post by: paperman on October 10, 2011, 05:14:17 AM
Did you add any lay-up chemicals to the waterside?  I have the plates all drawn up and am waiting on the shop to brake them.  I have an old 1000 gallon fuel oil tank.  It was removed from service and did not leak.  Thinking of using that for the outer tank.  I kind of torn, reuse a tank that is water tight and already made.  But the issue is what if it has a few pin holes in the making that I cant find and they open up later.  Now everything is built around a tank that is no good.  Im thinking of just spending the coin and building a real tank.   
Title: Re: Gasification wood boiler build
Post by: jackel440 on October 11, 2011, 12:37:27 PM
No I never installed the water treatment that i bought when i finnished building my stove.I knew i would be draining the stove to purge any other debri from building it that had setteled to the bottom.

Paperman, I would be planning to use that 1000 gallon tank to make hot water storage.Thats what I plan to do eventually is to have about 2K gallons of hot water super insulated in tanks to heat with.
Title: Re: Gasification wood boiler build
Post by: peacmar on October 13, 2011, 05:52:04 AM
Well, I must say... As a very experienced fabricator, welder, machinists and everything of the sort. Well done sir! I've followed this build in my free time since almost the first post and am quite amazed at the quality and effort of your build. I can appreciate your efforts as I know what went into this. I have some questions if that would be ok?
Title: Re: Gasification wood boiler build
Post by: jackel440 on October 13, 2011, 11:17:13 AM
Well, I must say... As a very experienced fabricator, welder, machinists and everything of the sort. Well done sir! I've followed this build in my free time since almost the first post and am quite amazed at the quality and effort of your build. I can appreciate your efforts as I know what went into this. I have some questions if that would be ok?
thanks for the compliments. I do love this kind of work.I enjoy doing it everyday at work.can be tough  getting the same results at home that you do in a Factory with all the right equipment.
Send me questions if you have them.I would be glad to answer them if I can.
Title: Re: Gasification wood boiler build
Post by: peacmar on October 13, 2011, 11:30:43 AM
I very well understand the frustrations that can be had by trying to achieve ones quality and efficiency at work in the shop at home. It's nice to have every tool needed at your fingertips at the job, but wish you owned them also. I have a few about your design concepts, as I am planning my second boiler build. And a few ideas on the controller I would like to compare thoughts with you. But first ill start with asking if you have any efficiency calculations yet? I would be happy to help in that department so everyone here can use the methods when designing their own burner. I just have to look back through and try to find all the necessary info. Fan cfm, fire tube size, secondary burn chamber dimensions. You have the temps in your video I recall that. The stack temp is the only one I can't remember seeing...
Title: Re: Gasification wood boiler build
Post by: jackel440 on October 13, 2011, 05:05:00 PM
I very well understand the frustrations that can be had by trying to achieve ones quality and efficiency at work in the shop at home. It's nice to have every tool needed at your fingertips at the job, but wish you owned them also. I have a few about your design concepts, as I am planning my second boiler build. And a few ideas on the controller I would like to compare thoughts with you. But first ill start with asking if you have any efficiency calculations yet? I would be happy to help in that department so everyone here can use the methods when designing their own burner. I just have to look back through and try to find all the necessary info. Fan cfm, fire tube size, secondary burn chamber dimensions. You have the temps in your video I recall that. The stack temp is the only one I can't remember seeing...
Yeah I do have most of what I need in my own shop.Just need to get a shear,leaf brake,slip rolls. ;D
No I dont have any efficiency calculations on it yet.I know it does seem to sip the wood from what I experianced last year.
If I remember correctly my fan is 500 cfm.The heat exchanger tubes coming from the refractory chamber are 3" diameter.There are six of them.I believe they are approximatly 3' long if I remmeber correctly.The dimensions are probably in a post somewhere back.
I will have to go back and measure the tunnel size.I think each tunnel is about 4.5" tall maybe approximately 7" wide now this is off the top of my head.
I never did get an exhaust stack temp last year.I started to several times but just never did. :bash:
I am working 12 to 16 hours the next few days so I will try to re check those dimensions sometime. ;)

I  just cut my feeder line to my house in half ,and I am in the process of running the lines to the shop .Then I have to rehook the house back up.I made a S.S. wall mount to run the feeder lines into the the wall of my shop.Plus it also has a 1/2" pipe nipple welded through it to allow the ability to have an air line on the back of the shop.I will have to get pics off my cell phone and post them. :photo:
Title: Re: Gasification wood boiler build
Post by: peacmar on October 14, 2011, 11:22:12 AM
I just got done working those kinds of hours myself the last two months straight. Those are some looooooonnnngggg days.

I studied past posts and it looks like your using standard splits for the fire brick. So I'm guessing that your secondary chamber dimensions are about 18" wide and 12.75" tall? Not including the fire brick, which I should have been more clear on, my apologies for that. I meant metal surfaces only.
Title: Re: Gasification wood boiler build
Post by: jackel440 on October 14, 2011, 05:17:32 PM
Yeah I believe your just about correct on dimensions.
Man these long hours are killer on a guy.Looks like it is going to be a long weekend for me.
Yes they are 1x4x9 hard brick if I remember correctly.
Maybe tomorrow i can check the dimensions after work.
Title: Re: Gasification wood boiler build
Post by: peacmar on October 14, 2011, 09:54:27 PM
So we have the tube size and roughly the secondary chamber size. I believe you stated that the whole works is 60" long, inside dimension? All that leaves is the surface area of the primary chamber, not including the floor. But each sides dimensions must be calculated independently, as the sides are considered horizontal flow because of the inverted draft, and the ceiling is actually more like a vertical surface as only radiant heat will reach this. 

No rush on the dimensions as I understand that not feeling like doing much after 14 hours of doing too much feeling. Keep well rested and avoid the fall temp swings. Long hours run down the bodies defenses real quick.
Title: Re: Gasification wood boiler build
Post by: bewford on December 13, 2011, 01:00:15 AM
any updates on how its runnin this year?? what about the efficiency calculations???
Title: Re: Gasification wood boiler build
Post by: jackel440 on December 13, 2011, 04:20:10 PM
She is running great so far.
I did modify the air feed tube in the burn chamber before the start of the season.I can't believe how much that helped it compared to last year.
I have been running since october ,and I have maybe used 2 cords or so.I haven't kept real good track like I had planned.Plus we have had lots of warm days.
I love how she just sips the wood,and also how she kept my family warm when the power was out for 3 days do to a bad,wet snow storm we got a couple weeks ago.
I do have some pics that need to be uploaded of some recent mods.
Title: Re: Gasification wood boiler build
Post by: beeman on December 13, 2011, 05:24:08 PM
man jackel  you and many others are so talented it makes me feel like hik
Title: Re: Gasification wood boiler build
Post by: tinner on January 22, 2012, 08:10:46 PM
Curious as to how you modded the air tubes?

Thanks for sharing all of this.

 :thumbup:
Title: Re: Gasification wood boiler build
Post by: jackel440 on January 23, 2012, 01:16:04 PM
Curious as to how you modded the air tubes?

Thanks for sharing all of this.

 :thumbup:
yeah I have to get those pics uploaded.maybe in the next day or so.
Title: Re: Gasification wood boiler build
Post by: jackel440 on January 23, 2012, 05:15:13 PM
I am going to try this link deal to a pic of the air tube.
The original air holes are round along the top and bottom of the tube.I plugged those as creasote was coming in the top and building up in the tube choking off air flow.So I then cut large slots and folded the tab inward to allow air to easily be forced around the airbox.
In the modified version you can see the big tab pushed inwards at the end of the tube.
https://picasaweb.google.com/113002591621979904221/WoodBoiler?authuser=0&feat=directlink
Title: Re: Gasification wood boiler build
Post by: tinner on January 23, 2012, 05:58:25 PM
Wow, I'll say you opened it up. And ready your posts, it is running very well.

Congrats and thanks again.

 :)
Title: Re: Gasification wood boiler build
Post by: jackel440 on January 23, 2012, 06:05:24 PM
Thanks and I apologize for not getting those pics up for you guys sooner. :thumbup:
Title: Re: Gasification wood boiler build
Post by: tinner on January 23, 2012, 06:12:00 PM
No apology needed. You have gone way out of your way to share,

 :)
Title: Re: Gasification wood boiler build
Post by: Drifter on February 20, 2012, 11:35:35 PM
Wow what a build. Serious time and dedication required for all that. I am a fabricator/ maintenance mechanic. I used to build pressure code in a special shop as well. Nothing can compare to the blood sweat and tears that goes into something like this. Cograts to you and your family.
Title: Re: Gasification wood boiler build
Post by: peacmar on July 18, 2012, 07:40:03 AM
Hey jackel, have you seen the new gasser units from natures comfort? I think they may have seen yours on here or somewhere and how well its working because they're new design is ironically similar to yours. And I can say that I know for a fact you dreamed up yours far before they did and we just built the units this past spring. I'd say they owe you a bit of thanks ($) for all the R&D you did ;D
Title: Re: Gasification wood boiler build
Post by: jackel440 on August 12, 2012, 05:41:56 PM
Hey jackel, have you seen the new gasser units from natures comfort? I think they may have seen yours on here or somewhere and how well its working because they're new design is ironically similar to yours. And I can say that I know for a fact you dreamed up yours far before they did and we just built the units this past spring. I'd say they owe you a bit of thanks ($) for all the R&D you did ;D
I haven't checked into them yet ,but I did hear that they have a radiused insert in the bottom like I did.I will have to check them out and see how i helped them improve thier product. ;D
Thanks for the heads up. :thumbup:
Title: Re: Gasification wood boiler build
Post by: sixmenn on August 17, 2012, 09:22:51 AM
If you have ? just holler and I will help if I can. :thumbup:

Hey Jackel.  I've looked at your build pictures over and over.  Awesome build, and many thanks for keeping us all informed.  Your work has sure helped a lot of people out in understanding gasification boilers better. 

I've got a build in mind and have a quick question in mind.  I see you put a bypass in, but I've seen other models that don't have the primary burn chamber with a bypass in it.  Do you think a by-pass is always necessary?

Thanks again!

sixmenn
Title: Re: Gasification wood boiler build
Post by: jackel440 on September 10, 2012, 10:02:13 PM
If you have ? just holler and I will help if I can. :thumbup:

Hey Jackel.  I've looked at your build pictures over and over.  Awesome build, and many thanks for keeping us all informed.  Your work has sure helped a lot of people out in understanding gasification boilers better. 

I've got a build in mind and have a quick question in mind.  I see you put a bypass in, but I've seen other models that don't have the primary burn chamber with a bypass in it.  Do you think a by-pass is always necessary?

Thanks again!

sixmenn

Yes I think a bypass is a good thing to have.When you load the stove you get less smoke coming back out at you while its running.I mean even when the blower is shut off.Open the by pass and then load wood.You get less smoke in your face.I also like the ability to open the bypass and run it like a conventional boiler.I wouldn't build one without it. :thumbup:
Title: Re: Gasification wood boiler build
Post by: avc8130 on September 13, 2012, 09:07:39 AM
So how has she been running?

Any chance you have "plans" you worked to?  I bet you could sell them!

ac
Title: Re: Gasification wood boiler build
Post by: jackel440 on September 14, 2012, 06:55:09 AM
Well she is working great.Well hopefully not for another month anyways ;)
I had drawings I made of my all my pieces for shearing them and bending them.Unfortunately I deviated from them as I went a bit.
I don't even know if I still have them.Not really worth trying to make and sell plans.
I figure if a guy has enough skill to build one he can design and engineer something to what he wants anyways.Just like what I did.
I am more then glad to give advice if I can give it. :thumbup:
Title: Re: Gasification wood boiler build
Post by: peacmar on September 26, 2012, 06:59:00 AM
If you have ? just holler and I will help if I can. :thumbup:

Hey Jackel.  I've looked at your build pictures over and over.  Awesome build, and many thanks for keeping us all informed.  Your work has sure helped a lot of people out in understanding gasification boilers better. 

I've got a build in mind and have a quick question in mind.  I see you put a bypass in, but I've seen other models that don't have the primary burn chamber with a bypass in it.  Do you think a by-pass is always necessary?

Thanks again!

sixmenn

Yes I think a bypass is a good thing to have.When you load the stove you get less smoke coming back out at you while its running.I mean even when the blower is shut off.Open the by pass and then load wood.You get less smoke in your face.I also like the ability to open the bypass and run it like a conventional boiler.I wouldn't build one without it. :thumbup:


Excellent advice  :thumbup:


A bypass also makes lighting easier. Start a small fire with some kindling with the bypass open, place a few larger pieces of wood on top of that and let it burn for about ten minutes with the bypass open, fill it full, close the door, close the bypass, and walk away. Where it burns like a normal burner the heat rises and ignite the larger pieces above the fire and gets you a bed of coals more quickly and more reliably.

A bypass also vents out the gasses that build up inside the chamber. Gassification releases hydrogen and carbon monoxide which are both very flammable. If you don't vent these out before opening the door you can get a pretty nasty flair up in your face when they light off upon allowing fresh air into the mix.
Title: Re: Gasification wood boiler build
Post by: angus1x1 on November 06, 2012, 09:34:35 PM
Wondering what the K-Wool is you used to insulate your doors?Maybe magnesium silicate?
How did the doors stand up to the heat?
I would like to do something similar to my doors instead of water filled-cooled.
Thx,Steve