Well I have finished up almost everything on the boiler and filled it with water. I built 2x4 walls around it and covered them with aluminized bubble wrap as a vapor barrier and radiant barrier. The wrap follows the curve of the tank underneath with a 10" space between the two that I blew in with cellulose insulation. The top of the tank isn't completely covered yet because i ran out of insulation. There was one leak in my welding coming from one of the ports on the propane tank that makes up the burn chamber. It was easy to access though and i welded it from the inside. The plumbing going into the house and underground line is all done also. Just have to bolt on the Primary circulator and solder a few copper fittings.
I started it up and found out there was not enough airflow. The fan was of poor design
lol Also the motor was not fast enough. My Dad had a 3/4 hp 3450 rpm motor laying around so that is now on there and i build a much stronger fan that had some real effort put into it. I balanced it by welding on the lighter side when it was held by two bearings. Also changed from direct drive to belt drive. It is easier to remove now and I can adjust the rpm if i need to. Currently turning at about 4000 rpm.
So thats where I am currently at. once i get the tank up to temperature I will fill the loop that runs underground and through the house then turn on the pumps.
I have burned two half loads of wood in it so far though (second one is still going)
My problem now is that it continues to smoke even when the fire seems to be going well.
I am not sure if it is because the entire tank is still very cold or if there is a design flaw.
The one thing i made quite different is the secondary chamber air source.
There is 4" coming from the back of the tank to the front and it runs into an air collar that covers the bottom half of the primary. There are holes cut to let air into the front of the firebox and also a bit of a manifold that directs air through two thin wall 2" tubes that lead through the coalbed and end in front of the secondary chamber.
When I open the door the fire does pick up a bit and then i see flames being pulled through the secondary but it doesn't appear to really be burning there and it is still smoking.
The first load I tested with was mostly kiln dried wood scraps and other waste wood. I thought it was burning too fast but the current load of wood were some well seasoned big splits. I left them quite big to try and make the whole load burn slower.
It is still blowing smoke though. I can adjust the air from the primary to the secondary but it doesn't seem to make a difference.
Anyone have any ideas on what could be causing it?
I thought it could be that the intake air isn't heated enough because the whole tank is cold but i'm not sure.
When the door is open the fire seems to be burning quite cleanly but it is still pumping out smoke.
Thanks in advance for any advice
I will post a bunch of pictures once I get the plumbing finished and the insulation done.