Laser cutting various parts for a hydrogen cell system.
The laser cutting machine is very useful for making many parts and some are shown here. The machine has been modified a lot since purchased and uses an additional oxygen to help with the cutting of some things. Plastics do not require this modification. Another video will be made soon that shows in detail the cutting of nylon cloth used for making the membranes of the separator cells. ... https://www.youtube.com/watch?v=wxkPxEqoi0k
Another happy customer. Yesterday we fitted a 4Nx4 cell and complete system to a 2.8 litre diesel. Today we took it for a long run of 260 kms to test it out. The customer couldn't believe the difference to his vehicle, his comments were "The fuel gauge is stuck....", "It's running much quieter, the ticking noise has gone...", It's got more power and is smoother..", "I can't wait to tell the wife how good this is..."
When we got back to our hometown, my customer went to see as many friends as he could find to tell and show them his new fuel addition to his vehicle, I think I am going to be busy for the next few months.
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https://www.youtube.com/watch?v=Ze7yahyu48E
Soon we will be releasing a new system for the heavy vehicles, and because of that a new power controller is needed.
The case for the controller has been thought out, but first it has to be tested before going into production.
The start the test a mock case is being made from cardboard, just to see it it will all go together nicely before spend a lot of money on the machining of the case parts.
This video shows the case being cut out ready for bending to shape and then fitting with all the electronics and the heat-sink and cooling fan.
Another video will follow in a few days or so of the finished controller, ready for installation.
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https://www.youtube.com/watch?v=6saU6fBcR_o
Trying out the Viper 30 for my DIY CNC plasma cutter.
Needs a bit of tuning to reduce the dross, but works OK.
Maybe increase the speed a bit so there is less dross, but it is easy to clean off anyway.
Making new parts for another DIY CNC plasma cutter, different design I am working on.
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https://www.youtube.com/watch?v=FAIyzK6thnI
Cell plates need to be passivated prior to use.
The process used to be done with nitric acid, which is dangerous and also have an environmental problem of what to do with the acid when finished. Nitric acid can burn your skin severely, and also can damage many things around it by just the fumes that come off it.
Today the favoured method of passivation is to use citric acid which is safe, governmentally friendly and cheap.
Citric acid can be sent through the post as it is a "Non Dangerous Goods" category,
The process is very simple, mix the citric acid power in some distilled water (3% solution) and warm to about 50C or 120F. I use an aquarium pump to pump the acid through a dry cell after it has been assembled, and any number of cells can be joined together so that all can be done at the same time.
Let the pump work for about 30 minutes and then drain and blow air through the cells or better still, oxygen.
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https://www.youtube.com/watch?v=jAxqAOflL-Q
When making hydrogen cells, either hho cells or separator cells, a number of gaskets are required.
These can easily be made and made quick and accurately by use of a gasket cutting jig as shown on this video.
The jig is made from two pieces of steel plate that are drilled together and dowel pinned to keep the hole locations accurate. A punch made from silver steel is used to punch the holes in the neoprene sheet.
Almost anyone can make a jig like this to suit the gasket that they need.
Learn how to make a set of gaskets the easy and accurate way for hydrogen cells or anything that needs a neoprene gasket.
The tools are simple and can be made by most people quite easily and the results are very accurate and quick. Not suitable for doing just a few gaskets, but if you have a need for many and don't want to pay the high fees for a water jet cut gasket, then this is the way to go.
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https://www.youtube.com/watch?v=DfALh7CWf-M
The Ford Transit is a real challenge to fit a system too. Not only is there little room to add the parts, but it has a strange none standard OBDII. There is no oxygen sensor and no cat converter. Because of this an hho cell has been installed to test. The cell has been made from left over separator cell plates, all new but a redundant design.
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https://www.youtube.com/watch?v=Hhm-QcRRg8s
I have an old bomb of a van that I will eventually convert to a hydrogen assisted vehicle using our new H2O Separator Cell that is about to be released soon.
This old car has really dirty plugs and was misfiring badly.
I used my hydrogen torch to quickly clean the plugs as I knew that hydrogen eats up carbon. It worked immediately, the job only lasted a few minutes and the plugs were as clean as new.
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https://www.youtube.com/watch?v=BrN2G2p_Ieo