WARNING
This project should not be attempted without adult supervision and adequate training.

Misuse, or careless use, of tools and/or projects may result in serious injury or death. Use of
this content is at your own risk, and you assume all responsibility for your actions.

The system, when in operation is under pressure and can be very dangerous. If seals or
connections fail, the electrolyte solution can spray out under pressure, and may cause
chemical burns and/or damage to objects that make contact. Respect and extreme caution
is required.

Use caution when mixing and using electrolyte. KOH is caustic and will cause chemical burns
on skin. Do not ingest. Use outside and away from people or property. Use gloves when
handling the electrolyte and operating the system. Seek advice from medical personnel if
contact is made with chemical.

Be aware of your surroundings, the wind, and where your gas may travel. Be aware of
potential threats.

Do not ignite gas in populated areas, around people or developments.

The contents of this packet in no way guarantee your success with the project, or express any
warranty associated with your use of these plans.

This packet is for informational purposes only, and you agree not to hold the author
responsible for any damages that may result from use of the information you receive herein.

This packet may not be copied, shared or distributed without the written consent of the author.
Failure to comply may result in legal action.

For purchase and permission requests, contact grant@thekingofrandom.com



 

 
  


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ASSEMBLY

PREPERATION: See my video at: http://youtu.be/GaGUEUxGKzE for thorough step by step

instructions.

GENERATOR BODY PREPERATION:

If you choose to go all ABS, you can buy a whole length of pipe, or just a 2 foot length from
your local hardware store. Either will work.

[ ] 4” Acrylic tube: Cut 1 piece to length of 7” (Can be substituted with 4” ABS pipe)
[ ] 2” Acrylic tube: Cut 1 piece to length of 5” (Can be substituted with 2” ABS pipe)

At this point you should be able to “dry fit” the two 4” clean-out adapters onto the 7” length of
4” wide tubing to test the fit. Dry fit the 4” clean-out plugs into the adaptors and verify they
screw together as desired. Also “dry fit” the 5” length of 2” wide pipe with the 2” clean-out
plugs to verify a snug fit.

Note: for cutting pipe, you can use a hacksaw or an ABS cutting tool. Power tools are an
option but can be dangerous and should not be used without adequate training.

GLUING MAIN BODY TOGETHER:

[ ] Read and follow instructions on the label of your “ABS cement” can.

Note: Only work on 1 connection at a time, and work quickly. ABS cement begins to set fairly
rapidly, and any delay may result in a failed connection.

[ ] Apply cement on surfaces that will be in contact, and twist together ¼ turn to ensure good
coverage, and push fully together.

[ ] Use a rubber hammer to help set the pipe in the adaptors all the way to the stops.

[ ] Coat the threads of the bottom clean-out adaptor, and clean-out plug with ABS cement,
and screw together with the top facing into the canister.

Note: Be prepared to screw in quickly and have a tool you can use to tighten it, because the
cement sets fast, and gaps may form if it's not screwed together all the way.

[ ] Let connections set for about 2 hours.

Note: If using acrylic tubing, clear silicone caulking may be preferred over pipe cement for
aesthetics.



 

 


ASSEMBLE BUBBLER:

[ ] Drill a 1/2” hole in the top of both 2” clean-out plugs and tap at 18 thread, if able, to match
the threads on the base of your 90º elbows.

[ ] Add thread tape to the two 1/4” 90º elbows, and screw the elbows into the caps so they
are water tight.

[ ] Take the tops, and plastic gaskets from the 2 trap adaptors, and slide them onto the
bubbler body first, then add the clean-out plugs to the ends. When those cap off the ends of
the pipe, screw them together with the trap adaptor pieces so they make a water tight
connection.

Note: Do not glue the bubbler fittings and pipe together, and do not over-tighten because the
plastic may weaken and fail.

GENERATOR BUILD:

[ ] Drill a 1/2” hole in the top of The 4” clean-out plug, and tap it at 18 thread as well.

[ ] Add pipe tape to a 3/8" swivel elbow with a 1/2” base, and screw that into place. (This is
mainly for convenience, and can be replaced by a cheap 90º elbow like the bubbler has, to
save on cost.)

[ ] Drill two 5/16" holes on opposite sides of the top of the cap. Leave just enough room for a
nut to be added to the bolt that comes through that later. These are the holes for the terminal
posts and will connect to the generator plates.

[ ] Bend the connector bands to 90º at the places indicated on the “Generator Plate Template”
page. The “U” shaped piece has two bends, marked at 1-3/4” from either end. The other 2
pieces are bent at 2-3/4”. I used my bench vise and a rubber hammer to bend them to 90º.

[ ] Cut a 5/16" course thread (18 thread) nylon bolt into two pieces 4" long.

Note: You may want to try screwing one of your jam nuts onto the bolt before you cut it, to
make sure they fit together. Also, make sure the bolt fits through the 5/16” holes in your
generator plates.

[ ] Add 2 stainless steel jam nuts (thin profile nuts) to the end of each bolt.

[ ] Push one bolt through one hole on the “U” shaped connector strap, and the other bolt
through the bottom hole on the shortest connector band. The bent part of the connector band
needs to be at the top and facing right, so it resembles the lower-case letter “r”. The plastic
bolts should enter from the right side, and be facing to the left, with the “U” shape on the
bottom.

[ ] Place one of the 1-1/2” x 6” plates on the bolts, and slide down until it rests on the
connector bands, making full metal contact.

[ ] Add a 3/4” diameter, 0.06” thick plastic washer to each of the bolts



 

 


[ ] Add another 1-1/2” x 6” plate

[ ] Add a jam nut on each bolt, and screw the bolts all the way down, until they tighten
everything together.

Note: At this point, you can check your initial connections from outside in; Outside jam nuts,
connector bands, plate, washers, plate, nuts.

The next few steps are pretty much a repeat of what you just did, except this time, use the
bigger plates.

[ ] Add a 3” x 6” plate

[ ] Add a plastic washer on both bolts

[ ] Add another 3” x 6” plate

[ ] Add a stainless steel jam nut to each bolt, and screw down tight so the plate assembly is
secure.

[ ] Repeat the above steps 2 more times until you have a total of 8 plates on your assembly.
6 of them are 3” x 6”, and the outer two are 1-1/2” x 6”

Half your generator is complete!

[ ] At this point, add the other connector band that looks like a “7” to the top bolt. The shorter
end needs to be at the top, so that both of the upper connectors bands are the same height.

Note: This is important because they will connect to the cap, and if they aren't the same
height, they may not fit properly.

FINISH THE GENERATOR

The next few steps are a mirror image repeat of what you just did to get to this point.

[ ] Add a stainless steel jam nut to each bolt, and screw down tight so the new connector
strap and plate assembly is secure.

Note: The bottom bolt should now have two jam nuts touching side by side.

[ ] Add a 3” x 6” plate

[ ] Add a plastic washer on each bolt

[ ] Add a 3” x 6” plate

[ ] Add a stainless steel jam nut to each bolt, and screw down tight so the plate assembly is
secure.

[ ] Repeat these steps 2 more times, and you should run out of big plates.



 

 


[ ] Add one of the last 1-1/2” x 6” plates

[ ] Add plastic washer on both bolts

[ ] Add the very last 1-1/2” x 6” plate

[ ] Trim the bolt ends using a hacksaw, or other method, so that 1/2” of the bolt is remaining
outside of the last plate

[ ] Connect the other side of the “U” connector band to the bottom bolt

[ ] Add a jam nut on each bolt, and screw the bolts all the way down, and use a wrench to
tighten the entire assembly together snugly.

[ ] On the other side of the generator, you can remove one of the outer jam nuts, so that you
can tighten the inner ones.

The generator plates are done. Now you can connect them to the 4” ABS plug (cap)

[ ] Add a nut to a 5/16" x 2" stainless steel bolt and push it through the hole in the right side
connector strap.

[ ] Add a 1/4" washer (stainless steel on one side, and rubber on the other) with the rubber
side up.

[ ] Repeat on the left side, and then place the cap on over the bolts.

[ ] With the bolts sticking through the holes in the cap, add two more washers, this time with
rubber side down, and secure with another nut on each side.

[ ] Tighten securely, and add a few more nuts and metal washers to the posts for
convenience. This will just help your jumper cables get a better grip if you hook it to your car
battery.

[ ] Dry-fit the generator assembly into the casing to check the fit. Ensure the plates are not
touching the casing, but hang straight down when screwed in.

ATTACH THE BUBBLER:

I used a bit of a creative method to attach clips to my generator with left over acrylic tubing
and rods. (See my video for details). If you're using ABS pipe, I imagine you can use the
same method using scrap pipe and ABS cement.

Other methods of securing the bubbler could include ty-straps, large hose clamps, or just
gluing the bubbler directly to the body.

This is where you can get creative and attach it as you desire.

[ ] Cut a length of poly tube at 20” and connect to the bubbler elbow

[ ] Optional: Cut a length of poly tube at 2” and connect to the generator swivel elbow, and



 

 


then to a one-way check valve.

IMPORTANT!: If the check valve is used, make sure it is inserted so that it will let gas out
FROM the generator, but will close if anything tries to go INTO the generator. Inserting the
valve backwards can lead to system overpressure, and catastrophic failure of the generator
body. In this case, pressurized electrolyte may explode or spew from the system and
contaminate surroundings, including anyone in proximity.

[ ] If a check valve is not used in your system, a 2” piece of tube is not required. Just connect
the 20” tube directly between the swivel elbow, and the bubbler.

PREPARE THE ELECTROLYTE:

Many people have tried different solutions. My experience has been with Potassium
Hydroxide (KOH) which was obtained at a local chemical supply company. KOH is caustic
and must be handled with care. It is the catalyst of choice because in 3 years of operating
this generator intermittently, no damage has been done to the generator plates, no corrosion,
rusting, dirtying of the solution, etc. As far as I can tell, the plates and assembly are about as
close to new as when I made them 3 years ago. However, results are not guaranteed. This
is just my experience with them.

[ ] Add 6 cups of distilled water to a mixing bowl

[ ] Add 2-6 Tablespoons of KOH flakes to the distilled water one scoop at a time. Add slowly
and mix carefully because the flakes heat up in the water. Wear gloves and protective
clothing.

Note: Adding more KOH will cause more current to flow in the generator, and more gas to be
created, however, the system will also heat up faster, and draw more electricity from your
power source. Adding too little won't show much result. 2-4 Tablespoons is probably best for
this amount of fluid.

[ ] Clean the inside of the generator body as spotless as possible. Rinse multiple times. Any
contaminants inside will be burned during operation, and will dirty the water and the generator
plates.

[ ] Filter the distilled water/KOH solution into the super cleaned casing. The fluid should fill
up to the bottom threads of the upper clean-out adaptor.

[ ] Add thread tape to the threads on the generator cap in a counter clockwise manner

[ ] Slowly insert into the solution, and screw in water tight. A wrench can be used to tighten,
however I've been able to get it water tight just by hand.

PREPARE THE SYSTEM FOR USE:

[ ] Remove the top cap from the bubbler, add any kind of water, then screw it back together.



 

 


Note: This water will help scrub the KOH that escapes from the generator, so over time, this
water will be contaminated with KOH as well. Always use protective gloves when handing
these solutions or be prepared to lose a few layers of skin from your hands and fingers.

Your system is ready for use, and hopefully you have a sexy looking hydroxy generator!

NOTE FROM THE AUTHOR:

This system produces an extremely powerful oxyhydrogen gas. An electrical current flowing
between the plates will seperate the water (H2O) into it's elemental gasses (Hydrogen,
Hydrogen, Oxygen) sometimes referred to as HHO.

If the gas is collected in a bottle, and ignited, the explosion can be dangerous and very loud.
Check state laws before burning gas in your area. Ear plugs should be mandatory, and a milk
jug full of gas can have a powerful enough shockwave to shake the windows on your house.

The gas will ignite even from a little static electric shock, so please use the greatest of care
when working around it as you never know when it could go off.

I've mainly used this system off my 12 volt car battery and produced about 1.5 liters/minute at
around 20 amps. Run the car while using the generator because the current draw is high
enough that it will drain your battery fairly quickly. With your car running, more of the load
should be supported by the alternator, and help preserve the battery.

For exponential results, I've hooked 2 car batteries in series, for a total of 24 volts. This
jumped the amps up closer to 50, and gas production jumped up over 5 liters per minute. The
system does get hot very quickly, and if left too long, the plastic can warp or melt.

When operating at high amps, restrict use as much as possible to allow the system to cool.
For longer continual use, use a lower voltage, or lessen the amount of KOH you put in the
water.

Your system is finished!

As a final note, I have not used this technology to operate any type of machinery or
equipment. It was mainly as an experiment in science to witness the electrolysis of water.

[ ] Have fun, be safe, and post a comment and a video response of your creation at:
http://www.youtube.com/video_response_upload?v=GaGUEUxGKzE

See my video at: http://youtu.be/GaGUEUxGKzE



 

 
   
   

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