We were concerned about crossing the border with the kit; we declared it as a wood gasifier and were sent on our way with no problems or additional paper work. We did some research on the possible duty before we crossed and had concluded that the kit was duty free … nice to have that confirmed at the border!Once we got the kit home the two drums of parts sat in the corner of the shop for over a month. A few days ago I finally unpacked the two barrels … there are a lot of parts! I purchased a GEK III V4.3, the most recent version that All Power Labs is building. The fabrication/assembly instructions for these kits are on the internet. As I unpacked I compared the parts in the barrel with a video from All Power Labs; the parts in the smaller barrel matched what was shown in the video, but the steel parts in the larger barrel were different in a few cases … right now I am assuming that some changes to the parts have been made since the video was made.After some emails with Julia Hasty (a technical specialist at All Power Labs), these are the instructions I am using for my project:
- The assembly instructions are at http://wiki.gekgasifier.com/w/page/27905807/Assembly%20Instructions%20for%20the%20GEK%20v4%20Kit,
- I read the above assembly instructions first to get an idea of the assembly steps (paying attention to the callouts for the v4.3 unit),
- I wound up on the following page for welding instructions for the GEK III … http://wiki.gekgasifier.com/w/page/24033107/GEK-Fabrication-Instructions
- The most recent instruction set is for V4.2
- I am assuming the page http://wiki.gekgasifier.com/w/page/45228987/GEK%20v4_2%20Fabrication%20Instruction (version 4.2) is a set of updates for the version 3.5 fabrication instructions.
- I plan to follow the 3.5 welding instructions with modifications from the 4.2 set,
- I am also following the fabrication videos provided at the above fabrication link.
I then fitted and tack welded the bottom plate of the cowling. The hardest part of this job wasfitting the plate, after every weld I would re-adjust the clamp to make sure there were no gaps between the wall and plate. After the bottom plate was tacked I then tack welded the top flange … again I adjusted the clamps after every tack to take the gaps out between the wall and flange. I then tack welded the seam of the cowling. I clamped the seam together as I tacked to keep the seam tight.I then welded the ash port, gas out and a third unidentified (see later) assembly; each assembly consists of a hanger and plate. Welding these assemblies together was straight forward, but I did haveproblems with the gas out assembly. The hanger for this assembly was too small for its intended cut out in the plate, leaving an air gap between the plate and the hanger along two sides and along the seam of the hanger. I had trouble welding the seam of the hanger due to the large gap … I was just blowing out the steel. I solved this problem by welding a 1/4″ round filler piece inside the seam. I am guessing there is a more elegant solution, but this worked for my skill level! I am also assuming that this filler will not be a problem for gas flow down the road.At this point I am a little stuck on how to proceed as the video does not exactly match my parts. I am wondering about the following:
- The gas cowling wall piece does not have a large diameter hole for a 1.5″ weld coupler. It does have a larger square cut out that fits the third unidentified assembly I welded above. I am assuming that this square assembly is a replacement for the weld coupler.
- The gas out assembly does not have a hole drilled in its hanger piece as is shown in the video. I think this is fine as the assembly instructions for the v4.3 GEK mention that the bung has been moved from the gas out assembly.
- There are two 3/4″ diameter holes that have not been dealt with in the gas cowling.