This project is very early on in its creation, But I thought i would start to document its production.
As a kid i had a mamod steam engine. Really good fun to watch and play with. I even used it to run some of my mecanno contraptions.
Growing up i was always tinkering with things, making machines out of scraps lying around the house, even taking apart my dads radios to get at the components (he wasn't very happy about it)
Roll on forwards to being 20, I'm a big boy now with bigger and more dangerous tools, like a blowtorch. I know next to nothing about metal work though, just a bit about brazing and soldering which i learnt when i was 13.
I plan to build completely from scratch a fully functioning steam boiler to run future projects like a beam engine or a grasshopper engine.
I know the theory and the basic working of them, seeing as engineering is my passion, and am currently studying mechanical engineering at manchester.
To do this i will need to build:
A gas burner to supply heat
A boiler (to boil the water in) (thinking of using a tin can)
A water level meter to make sure it doesn't dry out and over heat.
And if possible a way of using the steams pressure to force in water from an external reservoir into the boiler so that i don't have to wait for it to cool down to refill it.
I have already made preliminary work on a container for the butane gas and the beginnings of the gas burner manifold.
Here are my very basic plans with the butane canister and gas line. The gas line is 6mm brass pipe, i heated the pipe till red hot then bent it into shape, got a few burns on my hand and i only had a turbo lighter to do it with so it was very slow going.
[thumb]http://i.imgur.com/4XtHN.jpg[/thumb]
This is the gas cylinder, i scavenged the inlet valve from an old cooker lighter. By this point i had purchased a proper propane blowtorch so the job of soldering the end caps on the 22mm copper tube and the gas line was a hell of a lot easier and quicker.
[thumb]http://i.imgur.com/lmJ7G.jpg[/thumb]
I have some small needle valves coming in the post so until then i can't do much. Il post pictures of my tools, progress and general stuff as i go.
Magnificent, Sir.
Update, With better pictures seeing as I'm not too busy.
Here is the little burner section fitted onto the pipe previously shown. I blocked up one end and the reason that i looped it over was so that there would be an even flow of gas into both ends of the burner holes. And a few general pictures.
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And a couple more parts! yay!!
These are to fix the gas cylinder to a mount.
[thumb]http://i.imgur.com/9aUq5.jpg[/thumb]
This is a little screw cap to fill the boiler from.
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And here are my tools, guess what they are.
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really great craftmanship here.
Best thread in this section all year.
You must post a video on this when it's completed, I can't wait to see the finished product.
What materials/method do you use to solder copper?
Where I work at a school, we have a small metalworking section on the syllabus, and I'm doing a little research on silver soldering. So I was wondering if it'd be the best approach.
There won't be any complex welds, just basically securing copper rods and plates together.
[QUOTE=dead60;37482536]What materials/method do you use to solder copper?
Where I work at a school, we have a small metalworking section on the syllabus, and I'm doing a little research on silver soldering. So I was wondering if it'd be the best approach.
There won't be any complex welds, just basically securing copper rods and plates together.[/QUOTE]
Silver core solder is the best one to use, but i can't really afford it. I'm using acid core plumbers solder which melts at 220 degrees centigrade. (never ever use acid core on electronics, just for metal work/plumbing)
The method i use is thus:
1)prepare the joint by making sure they fit closely to each other, or on each other or in each other. 2)Make sure the work is clean by wiping it down.
2)lightly sand with fine grit the areas you want soldering, this helps the solder flow and bond with the surface.
3)flux the surface's, to much doesn't hurt it, too little and you risk the solder not flowing well.
4)heat the work and not the solder!! this is the important bit, heat the work around the area you want soldering, generally heat the "male" part, the bit that fits into the other part.
5)when hot enough (ive gotten good at telling, it's a trial and error thing to begin with) apply the solder like you would a glue. it will grip onto the surface and flow into and nooks and crevices in you work via surface tension and the capillary effect.
6)allow the work to cool, don't get exited and move the work when hot, the solder may not have solidified, more to the point you can burn yourself. And make sure to clean the weld afterwards, residual acid may corrode the copper a little.
Check out some videos on youtube for hints and tips.
Bonne chance. Il post a picture-graphic method when i next do some soldering.
[QUOTE=Mixed Sources;37482767]Silver core solder is the best one to use, but i can't really afford it. I'm using acid core plumbers solder which melts at 220 degrees centigrade. (never ever use acid core on electronics, just for metal work/plumbing)
The method i use is thus:
1)prepare the joint by making sure they fit closely to each other, or on each other or in each other. 2)Make sure the work is clean by wiping it down.
2)lightly sand with fine grit the areas you want soldering, this helps the solder flow and bond with the surface.
3)flux the surface's, to much doesn't hurt it, too little and you risk the solder not flowing well.
4)heat the work and not the solder!! this is the important bit, heat the work around the area you want soldering, generally heat the "male" part, the bit that fits into the other part.
5)when hot enough (ive gotten good at telling, it's a trial and error thing to begin with) apply the solder like you would a glue. it will grip onto the surface and flow into and nooks and crevices in you work via surface tension and the capillary effect.
6)allow the work to cool, don't get exited and move the work when hot, the solder may not have solidified, more to the point you can burn yourself. And make sure to clean the weld afterwards, residual acid may corrode the copper a little.
Check out some videos on youtube for hints and tips.
Bonne chance. Il post a picture-graphic method when i next do some soldering.[/QUOTE]
Ah, Excellent tips. Most of my research I gathered seems to go through the same processed you mentioned. Which is a good sign! Always nice to check with someone, (such as yourself) to make sure it's all good.
Glad i could help!
Update! The gas burner is finished, Got the parts today and immediately got to work, I must be getting good at this because i managed to get it all done in 30 minutes. There are no leaks, made double sure of that. i don't want the thing exploding on me. It flares up every now an again but thats because the gas needle valve is new and hasn't been run in yet.
The valve, 1/4 inch.
[thumb]http://i.imgur.com/VeqnS.jpg[/thumb]
The adapters, from 1/4 inch to 6mm
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Assembled!
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And working, Its adjustable as well, just very delicately so.
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With a lighter so you can get an idea of its size
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I'm going on a pub crawl this weekend so don't expect an update for a couple of days, going to be battling a hangover.
Absolutely glorious. Any plans to buy or build a small steam engine to run off the resulting steam?
Wow this is amazing, i'm following this thread.
Awesome, I've always been interested in building a small steam engine myself but have never had the time / money to spare, good luck!
Also are you sure a tin can would work? I can't imagine it standing up to pressure that well, maybe you should use a moderately thick bit of copper pipe and some end caps, kind of like that gas cylinder.
I haven't really got any pictures to update it with, But i can fill you in on what the final product is going to be. Essentially its going to be a ridiculous expresso machine. Once pressure in the boiler has built up then il siphon of the water using the steam pressure to force through a compacted coffee filter and into a cup.
It's going to be fun setting it up in a thermodynamics lecture, ha!
In the long run though i plan to have an adapter so i can run a steam engine from the boiler, but i'm starting simple. The design for the boiler is unchanged. Going to mount it this week onto a base board and il have some pictures of that soon, keep watching!
Give us some pictures!
[QUOTE=KillerTele;37833495]Give us some pictures![/QUOTE]
Will do, just managed to find a bit of 2.5 inch copper boiler tube on Ebay the other week, and I've built the mounting board and pins! Also have all the components a good sanding and polish, makes it look a hell of a lot neater.
Been a bit busy with my second year at university so i hope you can understand the gap between updates. Don't worry, still keeping up the project for your entertainment. Will upload some pictures tomorrow, just need some sleep, was an awesome night out in Manchester on friday, still haven't slept. oh the life of an engineer.
update on its way
[editline]2nd October 2012[/editline]
The pictures are pretty self explanatory, i got a bit carried away with the whole "take good photo's of it" ha!
Essentially i glues two planks of pine together and sanded it down smooth on all sides. I would have preferred mahogany but i couldn't find any. Il probably stain the wood using oil to give it a darker and more appealing shade. It will also bring out the grain of the wood which I absolutely love to bits.
The mounting pins are simply shaped parts of brass tube hammered into the wood and glued into place. They aren't finished all that well (bit rough and not straight) but i reasoned that seeing as thier not going to be the main focus of it it doesn't matter so much. Notice how much more brilliant the brass and copper of the burner are, fine grit sanded it and polished, although it tarnished pretty quickly so il have to look into sealing it with either a max or lacquer varnish.
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This is the 2.5" boiler tube, god it was hard to find. its 2mm thick and i did some calculations and with good end caps should be able to withstand a pressure of 9 to 14 bar! this is overkill as the machine will only be running at 2 or 3 bar, but its nice to know it wont explode on me.
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Cool shots of it running, very soothing light and really shows up the texture of the wood.
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Oh and i found my old lighter and took a picture, It's an Imco and pretty reliable, hasn't died on me in 3 years. Useful for lighting smokes in a thunderstorm.
[thumb]http://i.imgur.com/ciRMH.jpg[/thumb]
Any questions, feel free to ask.
This is great. Can we expect a video of it in action? :eng101:
If you want i can take and upload a quick video as it is now, wouldn't be very interesting. I guess i could mess around with editing the video to make it as such. interested?
[QUOTE=Mixed Sources;37898166]If you want i can take and upload a quick video as it is now, wouldn't be very interesting. I guess i could mess around with editing the video to make it as such. interested?[/QUOTE]
I'm sure everyone will agree with me here?
Do it.
I'd rather see where you are taking these shots, reflective black looks very good with wood and copper.
[QUOTE=Killuah;37982692]I'd rather see where you are taking these shots, reflective black looks very good with wood and copper.[/QUOTE]
Can do, sorry I'm taking so long over this, it's very much a "when I'm bored" project and I've been rather happily busy as of late.
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Bonus: my record collection. Well half of it. Makes very good wall decoration. (also, spot the copper pipe)
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I polish my desk quite regularly, can't stand dusty or marked surfaces. I do my work on a sheet of thin plywood i keep tucked behind my bed.
[QUOTE=Mixed Sources;37991709]Can do, sorry I'm taking so long over this, it's very much a "when I'm bored" project and I've been rather happily busy as of late.
[thumb]http://i.imgur.com/SAxow.jpg[/thumb]
[thumb]http://i.imgur.com/H17YB.jpg[/thumb]
Bonus: my record collection. Well half of it. Makes very good wall decoration. (also, spot the copper pipe)
[thumb]http://i.imgur.com/fOxIJ.jpg[/thumb]
I polish my desk quite regularly, can't stand dusty or marked surfaces. I do my work on a sheet of thin plywood i keep tucked behind my bed.[/QUOTE]
Jesus your room is goddamned perfect and awesome. I'm SUPER jealous, I always wanted an attic room!
Your alarm clock is goddamn massive.
[QUOTE=OvB;37998722]Your alarm clock is goddamn massive.[/QUOTE]
I'm a heavy sleeper, massive alarm clock for massive sleep!
Got an update for you fella's. Got the boiler finally sorted. I'll get some pictures uploaded tomorrow.
The thread title terrified me but you clearly know what you're doing so I'm a little less scared.
Not something to be cutting corners on haha
Uploading some photo's. Also started work on the water gauge so there's some pictures of that. I will give someone a cookie if they can tell me why it needs to be connected to the boiler from both sides, top and bottom.
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And I made an incense holder as a birthday present. had fun with the beating out of copper, took a while though.
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[QUOTE=Mixed Sources;38410159]Uploading some photo's. Also started work on the water gauge so there's some pictures of that. I will give someone a cookie if they can tell me why it needs to be connected to the boiler from both sides, top and bottom.
[/QUOTE]
To get an accurate reading :P
I guess if you have it at one end where theres less heat the water reading would be different to say the other end where there could be more heat?
[QUOTE=Warlord_1011;38410993]To get an accurate reading :P
I guess if you have it at one end where theres less heat the water reading would be different to say the other end where there could be more heat?[/QUOTE]
Close, But no banana. Here's a hint, It's to do with pressure.
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