Modular Stove Fabrication Procedure

Linked from Stove. Produced by with adherence to

See build below and installation here:

BOM

Master BOM - only 5 unique stock materials + fasteners. edit

Frame

• [12] - 4' long
• [18] - 2' long
• [6] - 1' long
• Total - 90', $217

Panels

Note: undersize red panels slightly so they fit within 2'x2' or 1'x2' panel areas.

• [1] 1'x2' (front door of ash chamber)
• [3] 2'x2' (front, top, and flue panel)
• [1] 19"x2' (flame deflector)
• [1] 19"x42" (ash tray)
• [2] 3"x42" (ash tray)
• [2] 3"x19" (ash tray)
• Total: one sheet; $100

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Mild Steel Prices

• 1/4"x2"x2" angle - $2.41/ft
• 1/8"x1/2"x1/2" angle - $0.66/ft (or 1/8"x3/4"x3/4" angle)
• 1/8"x4'x8' sheet - $100

Build

Fabrication Diagram Master Index

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Fabrication Diagram

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Annotation: Angle cutting and plasma cutting can occur in parallel. Start with angle holders for welding. As soon as frame members are cut and mitered - begin on frames. 2 people can work on frame. Start with ash tray panels, weld them. Weld door handles. 4 people on welding total - 2 on main and 2 on ash chamber. 1 person marks the metal - 4' sections - which can't be fed with stop. 2' and shorter pieces are fed with stop on ironworker.

Intro to Fabrication Diagram and process:

Step 1

Study Concept: 2 boxes with slideable cover plates clamped down. Ash tray and flame deflector plates side in similar fashion.

Step 2

• Cut angle for 2 mitered frames, just like for Power Cube 6. 1/4"x2"x2" angle BOM:

• • Use Ironworker for mitered cuts:

• • Result: corners fit together such that all metal angle form flat planes

Angle cutting time lapse:

Quality Control

• 3 corners fit so there is no more than 1/8" space anywhere
• length of members within 1/4" tolerance

Then, the build:

Step 3

• Plasma Cut all panels
  • Do not cut out hole in flue panel. Mark Exact location of this hole in situ once the roof hole has been made to make sure the flue is perfectly vertical.
  • Includes ash tray and flame deflector panels

Step 4

• Cut panel holders - [10] pices of 1/8"x1/2"x1/2" angle - 2' long
  • Data point: with stop in place, ironworker does these in about 10 seconds each. Stop setup: 2 minutes. Pieces held by hand.

Step 5

• Weld frame - all 1/4"x2" angle - as this:

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• • Mitered corners welded, ground flat
  • Rails for flame deflector and ash tray are not mitered

Frame time lapse:

Start with Raw Stove Frame, add Stove Rails, then weld on Stove Grate. This is all 1/4"x2"x2" angle. Completedf fire chamber frame:

• Grate data point: cutting is 20 seconds per piece for angle with stops. Clamp not used for cutting 1/4"x2"2" angle - can be held by hand, but springless clamp would be good.

Ash tray frame:

Step 6

• Weld all panel holder nuts to holders, and holders to frame
• Weld on holding nuts - technique:

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• Weld holders to frame. Use a magnetic holder to align the two.

• Mount panels

Step 7

• Weld ash tray

• Weld handles to doors
• Weld 12 grate pieces to frame (23" long angle, 1/4", like rest of frame

Step 8

• Plasma cut flue panel
• Plasma cut flue sections, including damper section
• Plasma cut flue section joints
• Fabricate damper

Step 9

• Lay brick foundation for stove as in Concept Drawing - 4' wide by 5' long, length facing E-W

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• • A bench can we retrofitted to north side of stove
• Stack ash chamber and burn chamber sections, against rear brick wall in HabLab, stove door facing west, 4 feet from window
• Mount panels and doors
• Insert flame deflector and ash tray

Step 10

• Build up Bricks on 2 sides of Stove

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• Install flue

http://instagram.com/p/RBahyvQvon/

Step 11

• Break flue exit out of glazed door side or through roof

Design Rationale for Roof vs Side Window

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Fabrication Considerations

• 2 additional angle joints and 2 additional pipe sections compared to flue pipe straight out the top

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Performance Considerations:

• Additional 4.5 square feet of heat exchange from 3' longer flue pipe, or 18% increase in heat output
• $215 materials cost + roof insulation + labor
  • 20 sf of 1/8" sheet - $60 at $3/sf
  • $155 for 20' of flue pipe cf $93 for 12' of flue pipe, 6", 14 gauge, cf $350 for Insulated Chimney Pipe

File:Stovepics.zip

Modify Front Interface

The front sliding door expands non-uniformly when the stove heats up, preventing the door from being moved easily.

A hinged door design is warranted. See Hinge