- 1). Install a prefabricated hydrogen generator chamber inside the engine compartment of the car. If you cannot find one pre-assembled, you can build one out of 4-inch diameter CPVC pipe according to the specifications in your guide book. The optimal length is as close to 18 inches as possible, while fitting within the confines of the engine compartment; don't build a generator housing less than 10 inches long. The best method and exact location for mounting the generator will depend on the shape of the vehicle's engine, available space, and specific parts used.
- 2). Connect a heat resistant hose from the water inlet valve of the hydrogen generator to a water storage tank. Mount the water storage tank to the vehicle's chassis, if possible, inside the engine compartment. Choose a storage tank that holds a minimum of five to ten gallons. Several project manuals recommend US Plastics Part # No. 8658, which holds 16 gallons. Tanks will include some hardware for mounting them inside the vehicle, but ultimately the best placement and method of securing the tank depends on the layout and available space of your vehicle.
- 3). Wire the hydrogen generator's electrodes to an electronic control unit with a soldering iron. It is possible to find this type of unit pre-assembled or you can make one yourself using the parts listed in a detailed project guide. "The Hydrostar" guide book calls this electronic unit a "HyTronics" module and lists the parts with numbers specifically intended to be purchased at Radio Shack retailers. Other project handbooks list parts differently but build the same basic electronic component.
- 4). Wire an indicator panel array to the electronic control module and the hydrogen generator housing with a soldering iron. How you build an indicator panel system and secure it to the dashboard is a matter of personal preference and the specific parts you use. The fastest and easiest way to connect an indicator system is to use a prefabricated system, such as a VDO-II08720 Custom Console which easily mounts to the dashboard.
- 5). Attach an adapter to the carburetor so that you can connect the hydrogen outlet valve of the generator housing to the carburetor of your car with a length of heat resistant tubing. There are thousands of carburetors, so it will benefit you to consult a knowledgeable parts distributor such as Impco Technologies, and explain your hydrogen conversion project and the make and model of your vehicle. The vendor will select and ship you the correct carburetor adapter.
- 6). Connect the hydrogen generator system's electrodes and the electronic control module to the throttle assembly of your car.
- 7). Calibrate the voltage and gas pressure of your system with extreme care. This delicate operation is a crucial part of the conversion process. If you start the engine before the hydrogen generator and electronic control systems are properly calibrated, you will damage the generator and the engine. Detailed project guides for hydrogen conversion will provide you with details and calculations relevant to the specific parts you've selected for your hydrogen system. This process will require some amount of experimentation to fine-tune the system.
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