Basic Alcohol Stove Construction



Burner Construction


Alcohol Stove Construction Introduction

Step 1 - Jets

Step 2 - Fuel Port

Step 2a - Open Jet Stove

Step 2a - Hybrid Sideburner

Step 2b - Pressurized Jet Stove

Step 2c - Chimney Stove

Step 2c - Low Pressure Sideburner

Step 3 - Trimming

Step 4 - Assembly

Step 5 - Final Touches

Build a Primer Pan

Advanced Techniques


Step 4 - Assembly

Now you must decide how you will put the two cans together.  Before you start, ensure that the inside of the wider (or soon to be wider) section and the outside of the narrower section are roughened up with fine sandpaper or steel wool.  The edges of the top and bottom sections should be clean and smooth if you want them to fit together without any problems.  SOS pads and water work great for smoothing/polishing rough edges.


One important trick is to bring the edge of a wider section just slightly over the narrower section and tape it there, then carefully get the rest of the wider section over the narrower one.  A shim made of a short length of aluminum from the side of a can with a rounded and polished tip may be required to accomplish this.







Options -









This option has its applications, such as for tops of open vented/chimney stoves where the top gets too hot for JB Weld or High Temperature RTV, and where an airtight seal isn't absolutely necessary.


If you would like to keep the two stove sections together without them slipping, you can try a sealant to glue them together or carefully poke a couple of holes with a pushpin through where the two sidewalls come together.





Wick (Optional) -

Some folks opt to add fiberglass insulation, perlite or something similar between the inner and outer wall of their stoves.  This helps soak up fuel and decreases the amount of fuel spilled when the stove is tipped over.  Depending on how the wick is used it can increase vaporization of alcohol or decreases it.  A wick does affect the performance of a open flame stove, but is very questionable for jet stoves that are closed off.



Sealing -

After a careful test fit, clean parts with alcohol and and use a toothpick to mix up some J-B Weld.  Spread a thin coat of epoxy evenly around the inner side wall of the larger section.


Option - High Temperature RTV will work to seal your stove, but isn't an epoxy like J-B weld.  It is easier to use, cheaper but lacks the strength that may be needed if you decide to set very large caldrons on your stove (which isn't recommended).  It may also take longer to completely vulcanize if you use much more than you need.  You should wait at least 24 hours before testing your stove and several days before you try any durability tests (determining the break point).


If you are making an open jet stove, hybrid SideBurner stove or adding an inner cylinder to your pressurized jet stove (for structural integrity), this is the time to insert the inner cylinder.  Just fit the inner tube in the circular fissure in the inside of the top piece facing down and carefully bring the bottom piece over them (opposite in the picture below).  A small bead of epoxy may also be applied inside the circular fissure of the top piece (or later after construction is complete) to give it a better seal.


Note - if you are putting together an open jet stove, it is actually easier to perform this step upside down.


Now carefully insert the narrower section into the wider section.  (See tape and shim trick at beginning to this step).  Then after you get the stove sections started over each other, smear on a light coat over the inner section for some added sealing.  If you have an inner tube, take care that you don't crunch it during assembly and you may also want to place a book on top of your stove while the epoxy is hardening to ensure that the inner tube stays firmly seated. 


If you used the slit method, you must add a bead of epoxy over each of the slits to ensure a good seal.


Clean any epoxy with a paper towel.  Wait 6 hrs then put it into a 250°F oven for 3-4 hours to finish curing the epoxy or wait 24 hours to completely harden at room temperature.



Proceed to Step 5 - Final Touches




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