Modular Stove Fabrication Procedure

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Linked from Stove. Produced by Marcinted.jpg with adherence to Oshwalogo.png


See build below and installation here:


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


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


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


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


Fabrication Diagram Master Index


Fabrication Diagram


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. Stove.jpg

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

Mitered corners with 2"x2" angle

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:


    • 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:


  • 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


    • 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


  • Install flue


Step 11

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

Design Rationale for Roof vs Side Window


Fabrication Considerations

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


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




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


Stovedoor1.jpg Stovedoor2.jpg Stovedoor3.jpg

Stovedoor4.jpg Stovedoor5.jpg Stovedoor6.jpg

Stovedoor7.jpg Stovedoor8.jpg Stovedoor9.jpg

Stovedoor10.jpg Stovedoor11.jpg Stovegasket111.jpg