Basically, Galvanizing Metal Without Acid

September 26, 2026 by Bryan Cockfield 15 Comments

As useful as steel and iron are to the modern world, their tendency to rust is a major downside. There’s a spectrum of ways to prevent it, from quickly slapping on a coat of paint to alloying, chromizing, or physical vapor deposition. For a middle ground accessible to the home shop, galvanizing is a go-to method of rust prevention that deposits a layer of zinc onto the metal instead, but even this generally involves the use of strong acids. This method makes galvanizing accessible without any acids. (Spoiler alert: substitute strong bases.)

Although the acids are omitted, the solution is caustic, so similar safety measures are still advised. The first step in the process is to dissolve sodium hydroxide into a container of distilled water. Metallic zinc can then be dissolved in the solution, with a bit of sugar and liquid soap to improve the finished quality of the coating. An electric current is applied to the solution, using a graphite plate at the anode and the part to be electroplated as the cathode. After some time, the part will be uniformly coated in a layer of zinc, which can then be brightened in a solution of only-mildly-acidic citric acid if needed.

One of the benefits of using a strong base to galvanize a metal part, beyond the preference of avoiding strong acids, is that this process can be better at plating parts that are non-uniform in shape, so things with deep crevices or other odd shapes that might coat unevenly in acid. If there’s a preference for electroplating with acid, there are some ways of producing one’s own using various methods.

Continue reading “Basically, Galvanizing Metal Without Acid” →

Making Better Rubies At Home

August 24, 2026 by Maya Posch 15 Comments

Not the prettiest ruby, for sure. (Credit: Gems of Science, YouTube)

Sapphires and rubies aren’t just pretty, they also got a range of practical uses. This makes it even more useful to be able to make them at home for obviously completely innocent experiments. Cue [Gems of Science] and his attempts to make good-looking rubies, without resorting to the brute-force laser blasting approach that [Styropyro] previously used to create murky-looking gems.

That basic method used involves blasting aluminium oxide with a laser, which results in a container full of what are technically gems, but – as the image on the right makes clear – not exactly the prettiest or easiest to shine up. Much of the problem here is that these are hollow geodes composed of countless tiny crystals instead of solid singular crystals.

Although there are commercial ways to fairly easily create large crystals from a small seed crystal, none of these lend themselves to a DIY hobbyist with just a garage to muck about in. This leaves one alternative: the flux method. Rather than melting the material that will be grown onto the seed crystal, this flux crystal growth method uses a solvent (flux) and temperatures that a home kiln can achieve.

These rubies may be small, but are very shiny. (Credit: Gems of Science, YouTube)

Of note here is also that it’s the addition of Cr³⁺ ions into the base Al₂O₃ matrix that makes a ruby into a ruby, by giving it its red glow. In order to grow crystals this way you need to pick not only a suitable solvent, but also use a crucible that doesn’t want to become part of said crystal. Unfortunately a platinum crucible runs into the thousands of USD, but a graphite crucible should do if you keep oxygen away from it.

For the flux molybdenum oxide was used, mixed with chromium oxide and aluminium oxide to provide the ingredients for crystal growth. Unfortunately added charcoal interfered with the molybdenum, ruining that batch. This led to trying out more crucible types to find a recipe that worked, thereby finding out that an ‘alumina’ crucible also contained silica, which poisons the reaction, resulting in only tiny ruby crystals.

Ultimately pure alumina crucibles seemed to work great, until they began to shatter en masse, resulting in pained wallet noises and the purchases of some pre-loved platinum crucibles. This worked really well, but now the flux was evaporating too quickly to enable large crystal growth, thus requiring additives to stabilize it. Along with temperature cycling to induce the growth of larger crystals, this finally generated some solid results. After a first batch of smaller rubies, next up larger ones of up to 10 mm were grown.

While cutting one of these large rubies to set into a ring it was clear that it was still rather flawed, with pockets of flux captured into the crystal, but with the basic method now more or less dialed in it should be possible to address these small flaws as well.

Continue reading “Making Better Rubies At Home” →

Turning Energy Drinks Into Rocket Fuel

August 15, 2026 by Maya Posch 13 Comments

Sometimes claimed to give you wings, energy drinks can, at the very least, be used to make rockets fly. This is what [Nate Scovill] did in a recent video, where cans of the sugary stuff are processed to give a rocket its proverbial wings.

The basic concept is so-called rocket candy, which uses the fact that sugar is a pretty decent fuel type that — when combined with an oxidizer like potassium nitrate — can be turned into solid rocket fuel. Naturally it’d be easiest to start off with a pure source of sucrose or sorbitol for the sugar, but what if you only have access to cans of sugary soda?

Removing the moisture from the energy drink was the obvious first step, as water and rocket fuel aren’t a great mix. Adding and mixing potassium nitrate to the resulting thick syrup created the fuel-oxidizer mixture, also known as rocket fuel. This did take a detour involving removing the carbonation using a vacuum chamber, as CO₂ and fire do not really like each other either.

We previously covered making your own rocket candy, though it’s far from the only rocket fuel that can be made at home using products bought at the local supermarket. Obviously, doing so comes with a whole heap of risks, not least of which is the notion that the difference between a rocket and a bomb is a pretty thin and fuzzy line that you do not want to accidentally cross.

Continue reading “Turning Energy Drinks Into Rocket Fuel” →

Polystyrene Foam Can Be Gasoline With Some Help

August 4, 2026 by Maya Posch 25 Comments

Styrofoam – or closed-cell extruded polystyrene (XPS) foam if you want to be precise – is one of those materials that is both super versatile for packaging and insulation, but also a menace when it comes to disposal, even if you ignore that the monomer styrene (C₈H₈) is a known mutagenic toxin. One of the more creative ways to deal with the metric tons of polystyrene waste generated each year is to turn it into gasoline, as demonstrated by [Lowered Expectations] in a recent video.

With polystyrene being just another hydrocarbon polymer, the idea of turning these polymers into the mixture of hydrocarbon chains we call ‘gasoline’ isn’t so crazy. The problem is mostly doing it in a way that makes some economic sense and doesn’t risk turning your domicile into a hazmat risk site or threaten the health of you, your loved ones and the neighborhood.

The method demonstrated in the video uses fairly basic methods involving pyrolysis and distillation. The first step involves dissolving the polystyrene in gasoline that was previously recovered from stale gasoline, which is another dangerously fun science experiment. This creates a thick slurry that’s then put into the distillation flask for the heating phase.

After testing the distillates for spark ignition the useful distillates were combined with fuel stabilizer added. Before tossing this into a gasoline engine tank for further testing, the concerns of auto-polymerization of styrene monomers are addressed, which requires special inhibiters.

Although this mixture runs a gasoline generator just fine, a borescope inspection of the cylinders showed a build-up of a shiny, gummy residue. There’s also the issue that this mixture contains styrene monomers, which are as noted very unhealthy to breathe in from either the fuel or any remaining monomers in the exhaust. Definitely not something to try at home, basically.

Continue reading “Polystyrene Foam Can Be Gasoline With Some Help” →

Turning Fruits Into Ethylene And Ethane Refrigerant

August 2, 2026 by Maya Posch 11 Comments

One of the best parts about DIY chemistry and physics projects is that you get to decide how early in the supply chain you want to begin, such as with [Hyperspace Pirate]’s adventures in ethanol production from sugar fermentation. Although you can certainly just buy packs of sugar and yeast from the store and pretend that this will be helpful once the world embraces its Mad Max era, you may as well start with the stuff that actually grows on trees, like fruit.

While you could use the ethanol produced this way as ethanol fuel in combustion engines and the like, you can also turn the ethanol into ethylene and ethane. That way you can fill up your refrigerator, freezer, and air conditioner to keep your perishable foods and yourself fresh as the outside world descends into highly questionable fashion choices.

Even outside such a scenario it makes sense to generate your own ethane and ethylene, due to how much these refrigerants cost. Once you have the ethanol, some aluminium oxide catalyst at 350°C is enough to produce ethylene and water. Producing ethane is admittedly a bit more involved, requiring acetobacter bacteria to produce acetic acid, along with baking soda, a platinum anode and a few more odds and ends.

Producing butene and even longer chains from ethylene is also possible as a next step, but this gets even hairier than producing ethane from ethanol, so we’re likely to see this in a future update after all the low-hanging fruit has been harvested.

Continue reading “Turning Fruits Into Ethylene And Ethane Refrigerant” →

How To Rebuild An 1800s Victorian Leclanché Cell

July 6, 2026 by Maya Posch 20 Comments

The 19th century was an absolutely electrifying era, including in a literal sense. Although the phenomenon of electricity had been known by that time for centuries, actually making it do useful work was a much taller order. Aside from big, coal-powered generators, there also was a need for a more compact electrochemical solution, such as in the form of a wet or dry cell. One of the first major commercial successes here came in the form of the Leclanché cell, such as the genuine version that [Big Clive] found in an old UK building’s attic and has now revived.

Invented in 1866 by French scientist Georges Leclanché, the Leclanché cell features an ammonium chloride electrolyte solution, carbon cathode and zinc anode. There’s also a manganese dioxide depolarizer for preventing hydrogen build-up. Here water is the solvent for the ammonium chloride (also known as sal ammoniac).

The version that [Clive] got his grubby mitts on features a glass container, an already partially consumed zinc electrode and a slightly cracked porous ceramic tub that contains the carbon electrode and the manganese dioxide. After placing the components inside the specially shaped glass jar and filling it with an electrolyte mixture of one part ammonium chloride and four parts water by weight, the cell starts generating its approximate 1.4 VDC.

This type of wet cell was very popular, being essentially ‘rechargeable’ by topping up the water and replacing the zinc electrode consumable. They did suffer from a voltage drop-off during use due to increasing internal resistance, something that got improved upon with the zinc-carbon dry cell. Itself effectively an evolution of the Leclanché wet cell.

From there zinc-carbon dry cells got replaced with alkalines, which itself got mostly replaced by NiMH and Li-ion cells. Despite more than a hundred years between the electrochemical cell that [Clive] featured in his video and today’s batteries, it’s clear that this wet cell was quite literally just the Victorian-era equivalent of an alkaline AA cell.

Continue reading “How To Rebuild An 1800s Victorian Leclanché Cell” →

Microdistillery For Microchemistry

July 3, 2026 by Bryan Cockfield 21 Comments

Much like radio operators being encouraged to use the least possible amount of power to make a contact, chemists have a similar rule encouraging using the least amount of materials in experiments. Not only is this rooted in economics, but in safety as well; if something goes wrong it’s generally good if there’s not excess amounts of reactants. With modern techniques, though, it’s possible to bring experimental chemistry down to incredibly small scales, and [Marb’s lab] found that they needed a custom built still for these new, diminutive experiments.

The first step is to build the heating component of the still. This is provided with a few custom aluminum parts for the base and a pair of heaters originally meant for 3D printers, with the assembled unit wrapped in insulation. The heater accomodates a 25 mL round-bottom flask. Temperature control of the heating mantle is provided by a controller mounted to a DIN rail which receives power from a 24V power supply, and an additional temperature probe is added to measure the temperature of the distillate. A test run with water shows the small still quickly and efficiently evaporating the water up to a condenser.

Although building a still doesn’t have to be technically difficult, building something this small that’s effective and safe is a bit more challenging than a backyard moonshining operation. Scaling chemical reactions down can often be a challenge but is possible with the right mindset and equipment. We’ve seen miniaturization of many things that we might not have expected including hydrogen production, aluminum smelting, and even the construction of a microscope.

Continue reading “Microdistillery For Microchemistry” →