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Hi gang.
Well, I've been telling a few of you that I was going to install an on demand Hydroxy gas Generator unit onto my 5ht gen VFR.
I've had conversations with tightwad about how many additional watts can the 5th gen's charging system put out to power the Cell.
Codewriter along with a couple of othes have been a godsend with PC V information.
This last Sunday, I finally got 99% of the installation finished and my VFR is back on the street.
I can already hear the questions.
What is HHO or Hydroxy gas?
Why would you want the generator on your bike?
Why/How did you get involved with this stuff?
So let me lay out a little history and cover some of the basics.
I was a Mechanical Engineering major in college, one of the Senior design teams that I Schlepped parts and turned wrenches for was doing research into Hydrogen powered cars. I had many conversations with the team Mentor and a couple of the smarter members of the team about what was wrong with both gasoline (and diesel) fuels, as well as ethanol fuel and hydrogen.
The issues all boiled down to this handful of issues.
One gasoline was originally a waste product in the petroleum refining, but it has high energy density (34.2 Mega Joules/liter, consumed in one second that's potential to do 45863hp of work). When oil was more available, it seemed like a good choice for fuel even though most IC engines waste 75-80% of the energy. Thanks to its high energy density, it's relatively slow burning, so it's easy to design a safe transport vessel for a mobile vehicle. Pump gas these days is a blend of up to 87 various hydrocarbons and other additives (most additives are more waste products from the refining column).
Ethanol is not as dense (its only 24 Mega Joules/liter, which is about 32185 hp), but has the features of being a renewable natural product and it is a single hydrocarbon. The downsides are that it takes a lot of energy to distill the fuel, which drives up its unit cost. Its a less energy dense fuel compared to gas/diesel as well. There is also no infra-structure to supply it to the average consumer. Slow Stable burning, single compound, but hard to make and harder to find a commercial supplier.
Hydrogen on the other hand is a rapidly burning clean fuel, explosive is how some people would describe it. Its hard to store since it has to be highly compressed (like 600+ psi) or chilled to a liquid (-435 F approximately). So tank for carrying Hydrogen is either very large and thick to withstand the pressures or its large due to is extreme levels of insulation. Even recent breakthroughs in storage with metal matrices have issues with repeatedly filling and discharging cycles. The simplest process to produce Hydrogen is electrolysis. You take a tank and fill it with water and a source of ions (something as simple as some table salt can work), install two plates and close the tank except for 2 ports over each plate to release the gas produced. Run direct electrical current through the "cell" and it will produce Hydrogen gas at one plate and oxygen at the other.
Still that takes a precise voltage and current for the design of this two plate cell and its not very efficient.
So Hydrogen is almost unstable, its hard and expensive to make in quantity, it takes more power to make than it gives back when burned and god help you figuring out how to put it in a tank for the car or bike!!!
BUT just wait a minute, what happens if we allow the two gases to be collected at a common port?? Well now you have very reactive "monofuel" called HHO or hydroxy gas. Its a perfect stoichiometric blend of H2 and O2. If ignited it will rapidly burn and produce WATER!!!!. So if you change your generator cell design to a common outlet port, you can stack cells like a battery. Essentially planning the required input voltage and currents based on the plate materials, the area of the plates and the number of cell in a stack.
And now these cells are still a bit more than you want to try to fit to entirely provide fuel to an ICE.
But wait a minute.
Adding a moderate amount of Hydroxy gas to a gasoline or diesel engine, can radically change the rate of combustion in the cylinder. It accelerates the rate of combustion of the primary hydrocarbon fuel (Gas, Diesel, Ethanol, etc). This leads to more pressure on the piston on the power stroke so there is more torque, less heating of the block, and less unburned hydrocarbon fuel going out the exhaust port.
Less waste, less heating of the block and even some more power.
OKAY Now That the science lecture is out of the way, on to the installation.
Well I got my hands on One of these cells
In fact the cell in top pictures IS my cell.
The main tank for my bike was custom fabricated and I knew I'd need a small pump owing to the orientation of the cell to the tank.
So I set out to install it under the seat on my 5th gen. I guess it was pretty typical as I had not done a much under there.
the back
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and toward the front
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Well played around with it a bit and eventually ended up with this rough mock up (sorry the picture is blurry but I was holding parts with one hand and trying to snap a quick picture with the other.
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you'll see better in a moment.
The first order of business was moving the relay I had installed to switch power to the heated grips. That went well and I ended up re-using it to switch a BlueSea's fuseblock on with the ignition.
Next was moving the pcm forward
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Here the pcm is up and out, the great wiring harness unwrapping begins
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Onward we went. Trimming pretty much all the plastic ribs, the bump and most of the bottom of the pcm pocket from the undertray. Gotta love those oscillating flush cutters. Some carefully pushing and shoving, a little bit of drilling and lots and lots of wire dragging and I got to this point.
here is where I located the pump, and right below it the new relay for the new stebel horn.
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Well there the cell sits roughly in the middle of undertray, right where the tool kit and a u-lock were supposed to go.
Its strapped well down and the seat's hooks have been slightly trimmed at this point to allow it to sit there
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Now from the side you can see how high in the undertray the cell sits and you can also wonder where the main tank is as it's not visible from this angle.
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here are the shots of where main tank is and the fitting running to and from it.
first the rear view
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then the view from below
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Note one large fitting to fill the tank, one large fitting running out to the pump and four small lines returning from the cell.
This is four cell unit and each small hose runs all the way back to the tank to prevent current leakage between cells.
Moving around to and up to the left side you can see the intake supply hose as it leaves on its journey to the bubbler/drier as heads to intake.
you can also see the pcm relocated to just behind the battery along with the bluesea's fuseblock. The powercommander is stuck up under rubber skirt hanging off the tank hinge and will share that space with the autotune module when it arrives.
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Note the cables to the fuseblock are from my battery charger, I was using that to test out the cell for output and to search for leaks.
these next four photos show just how little space is left between the cell and seat.
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Now lets head towards the front and you can see where I mounted the bubbler/drier. This has two purposes, one it scrubs any water vapor and/or traces of electrolyte out of the gas before it goes to the intake. Two, it acts as a backflash arrestor, HHO a very reactive gas and in a back fire will go all the way back to the main tank and possibly blow it up.
If you have ever seen a nitrous oxide backfire, that's the kind of sudden reaction we don't want. So we put this inline.
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I'll make a nice bracket for it down line a bit (Like a couple of other things), but for now that's were it is going.
Here is the final money shot, all buttoned up and idling away with HHO flowing
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When I did fire it up with the cell running (its drawing about 9.5 amps, that's counting the 1.2-1.5 amps that pump draws as well), the idle when warmed up is about 650 rpm higher than before and it takes for ever to get really warm.
I'm thinking I have to bump the PCV's engagement temperature down from 165F.
I still have to get the autotune installed and I need to work on a few other little bits.
I also think I'm going to be going with a bunch of led bulbs to keep the power requirements down, but for now, I'm just trying to get out ride it.
Mileage and dyno numbers will follow.
Edited May 12, 2010 by HispanicSlammer