Modular Stove Fabrication Procedure

BOM

Start with BOM.

Frame

• [12] - 4' long
• [18] - 2' long
• [6] - 1' long

Panels

Note: undersize 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)

edit

Mild Steel

• 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

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

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
  • Includes ash tray and flame deflector panels

Step 4

• Cut door and panel holders from 1/8"x1/2"x1/2" angle

Step 5

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

edit

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

Step 6

• Weld all panel holders and door slides
• Weld on holding nuts

Step 7

• Weld ash tray
• Weld handles to doors

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
• 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
• Install flue

Step 11

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