How to make your own heat exchanger

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How to make your own heat exchanger
I have made three types of heat exchanger so far, each using a slightly different design. The first was a simple water over oil double tube heat exchanger with a 15 mm central pipe held within a 28 mm pipe. The second was inspired by the picture I was sent by Stephan Helbig from Germany who made a similar heat exchanger made with a coil of micro-bore wrapped around the central copper pipe. The third version has two stages so the fuel is warmed before it goes to the normal fuel filter (avoiding the need for the extra Peugeot filter I fitted to our VW Passat). The heater we sell is a three stage unit with an electrical boost which comes on only when the glow plugs are activated or when the wwater temperature is below a set limit.



8/12/2011 How to make your own heat exchanger The external coil looked easiy to make.bio-power.htm 2/3 . I then poured the salt dust into the pipe using a small diameter plastic funnel taped to the end of the pipe. I have not tried using sand. the bungs can be removed. and you take great care to fill the tube without any air gaps inside. Ready to fill the micro bore with dry salt before coiling When the coil is formed.co. and the salt shaken out of the pipe whilst rotating it slowly. which I had first dried in the oven and then ground to an almost liquid dust with a Moulinex electric soup blender. It will be necessary to tap the sides of the coil with a wooden spoon to release the salt. The rest of the heat exchanger is made from standard Yorkshire plumbing fittings. Fine salt dust stings your nose if sniffed). I then closed the ends of the pipe with wooden pegs to prevent spillage of the salt. because I imagine it may be more difficult to remove the sand. (Beware. It may take a while but it does all come free in the end. but in fact it was quite tricky to make a neat job! It is essential to fill the 8 mm micro-bore pipe with fine dry sand or salt before attempting to bend it around the core. Keep tapping the sides of the tube as you fill it to shake the salt all the way down to the bottom. to enable the salt dust to fall out from the lower end. I used salt. Instead of using salt it is possible to fill the pipe with water or oil and clamp the ends. otherwise the pipe simply buckles. It also helps to use a block of wood with a grove in it to hold the pipe as you can easily distort the soft pipe if you exert pressure using your naked fingers. If it does not clear completely then you will have to soak it in hot water to dissolve out the salt. Notice how the nozzles for receiving the rubber pipes are extended using half of a straight connector so the two solder rings make a convenient trap for the jubilee clip to www. Salt seems to work well so long as it is very dry.uk/exchanger. It is possible to get quite a tight fitting spiral to the micro-bore pipe if you twist the pipe as you form the coil.

The whole heat exchanger is then wrapped within a thick pipe insulation tube. John Nicholson September 2005 I hope you found the information on this site useful.8/12/2011 How to make your own heat exchanger grip the rubber pipe between. It may be better to braise the joints rather than use solder as the water can get very hot and melt the joints if the engine boils.htm 3/3 . When using the double flow heat exchanger.uk www. Return to main bio-power site index. however I can hear some people saying that the radiator is all made of soldered joints anyway! I also attach a wire strap around the coil to keep it tightly secured to the 28 mm copper pipe.co. the supply fuel goes around the coil and the return oil goes through the middle pipe. and then I run plenty of solder around the coil to weld it to the copper pipe as much as possible. or e-mail us at info@bio-power.uk/exchanger. Do not hesitate to contact me on 01286 830312 if you have any further questions.bio-power.co. Two stage heat exchanger ready for soldering the coil to the main water pipe Detail of one end showing method of forming outlet and inlet ports.

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