[BiggKidd]

A fellow on another site wanted pics of the carnage, so I’ll post it here too.

[BiggKidd]

Made some decent progress today. Finally got the last piece of the stove itself made. Have to finish welding it on, create the exhaust and install the three secondary air intakes. Then I can start fitting it in the outer case or mass box. There’s still a lot to do even after I get the case around it…

[BiggKidd]

Ya know the old saying time flies when you’re having fun? It must also apply to when you’re working and get in the groove. Here I thought it was about 2 and it’s after 5:30. Oops Oh well I did make some dang good progress today. I got the rest of the inner body of the stove all closed up all that’s left on the inside is the fresh air intakes and the last bit of exhaust where it will exit the case but I need to test fit it first so I can see how to work things out which means I need to start working on the base next.

[BiggKidd]

Took a couple old commercial metal shelf bases and made them in to a 34×36 inch base for the stove. Cut up some old sheet metal and welded it on for a floor surface. Then I got the two washer skins and cut one apart for the back and bottom of the stove case. Hopefully the weather holds off and I can start fitting the inner workings and the case together tomorrow.

[BiggKidd]

Only made a very little progress on this project today. I did get the case mostly welded together on three sides, the fourth side will likely be screwed together for reworking or repair later. I also got one of the three secondary air intakes made and welded in. I had other stuff that had to be done today before I could play with my project.

[BiggKidd]

Made a little more progress today. Got the exhaust cut through the case and welded it to the burner section. So no more taking the burner out for any reason. lol After that I got the other two secondary air intakes made and welded in place, just have to weld the bottom edge yet, couldn’t see well enough to weld that last 2 inches! once they are done then I have to make an adapter to seal all the inlets through the case openings and figure out just how to make the feed chute and air cutoffs. I want the air to cut itself off when the stove runs out of fuel so I’m thinking a simple flap door the wood will hold open until it’s gone then the flap will close dropping doors across the air intakes. At some point I have to remember to put the electric heating element and cross bar(s) in along with a water heating pipe. Getting closer to the end with every small step. I sure hope this thing works cause if not I’ve wasted a ton of time and resources!

[BiggKidd]

I’m to that point where mistakes can be really costly like the one I made a little while ago that caused a design change. Simply because I screwed up the order of progression. I HAVE to make sure that doesn’t happen again! I am down to the final assembly and the devil is in the details and putting things in in the correct order… Still quite a lot to be done including 8 feet of rip cuts relying on battery powered tools is going to take FOREVER!

[BiggKidd]

Made some good progress today. Finished cutting the feed chute and started assembling it. Got the trap door made and welded in to it. Then test fit all that and it’s ready to finish welding tight. Also got the pieces cut and ready to weld for the air intake shield.

Starting to feel like a never ending project here!

[BiggKidd]

I kicked butt and took names today! lol First I welded the wood rests in place then I welded the lower air intake on with it’s backing plate. After that I put the two cross bars in place to help prevent the weight from blowing out the center. About this stage I welded the feed chute in. Once that was in I cut the opening in the front panel and slid it home then screwed it tight. I still need to fasten the secondary facial backing plate and install the electric element and the basic stove will be about ready.

I do still have to make the pony firebox and chimney yet.

I may actually finish tomorrow if the weather is decent, long overdue!

ETA: Then I have to figure out how in the heck to move it! YIKES!

[BiggKidd]

Installing the water heating pipe should have, would have been a piece of cake IF I had remembered to do it BEFORE installing the front panel. But no I forgot to install it first so I spent about 2-3 hours working it in today and ended up with a sloppy job and not the nice clean install I was looking for. Worse the way I had to put it in will require a pump to be running If I had remembered to do it like I had planned the pump would have been optional. Oh well like spilt milk it’s done now. I got the hole for the electric element cut and got that almost ready to assemble. I still have to rip a 1/2″ copper pipe down to make some copper bars to hook the element up with it being recessed dang near to the middle of the unit. I just don’t have any wire I trust at 500F or possibly more. Once that’s done I have to make the air inlet doors and I “think” the stove build itself will be finished. The bad news is it’s supposed to rain all day tomorrow.

[JR2911DonnaW]

I have to ask, What is a pony firebox?

[BiggKidd]

I stole the name from the small pony engines they used to use to start large diesel engines back before tech found better ways.
This will either require a blower or another small fire near the chimney to get a draft started to get the main fire going. Only time will tell. In this case the pony fire is a smaller fire near the chimney exit to help get the draft going for the main fire. Once the main fire is going it should be able to maintain enough heat / draft to keep the fire burning strong. I’m praying it doesn’t require a blower to run period!

• This reply was modified 1 year, 2 months ago by  BiggKidd.

[BiggKidd]

Got the copper cut down and got the heating element section made. It’s a hunk of 2 inch stainless steel thin walled pipe and I needed to attach it to half of a 1 in cast iron pipe coupler so the element will screw in to it. The stainless pipe gives a no contact zone for the copper connector bars for the + and – while moving the element closer to the center of the unit. Sadly JB Weld was the best form of adhesion I could find and it’s only good to 550F so hopefully it’ll hold. It’ll probably see that temperature and more. While that started curing I got busy making the air intake closer. After much searching I found a piece of scrap steel close enough in size I didn’t mind cutting it down. It is a bit thicker than I was planning on and so therefore heavier. I needed something heavy enough to close the trap door but not so heavy as to stop the wood from passing through. Hopefully I can find that balance point using this piece I’m working on. Rain got here again before I was able to get more done.

[BiggKidd]

Going stir crazy two days of crap weather back to back is killing me. I NEED to get outside and do things before my crazy switch flips!

I had to order another diamond cutoff wheel, turns out I’ve worn the first one out. I will say it made a WHOLE lot of cuts including 4 or 5 24 inch rip cuts.

Also got the replacement modules ordered to replace the ones that got burned.

Starting to feel like a never ending project here!

[BiggKidd]

Holy crap guys I think the main body is done. I need to triple check it to be sure and then build the pony firebox and chimney. I’ll never know how I get so lucky but the automatic closer looks like it worked from the first try. Totally shocked me, I fully expected to have to make a hundred adjustments, different linkages etc. but nope it just worked, I’m really just blown away. It’s not perfect but it opens and closes fully.