Junk Bin Build Lets You Test Fuel Injectors On The Cheap

Fiddle around with cars long enough and you’ll realize two things: first, anything beyond the simplest repairs will probably require some kind of specialized tool, and second, those tools can be prohibitively expensive. That doesn’t mean you’re out of luck, though, especially if you’ve got scrap galore and a DIY spirit, as this junk bin fuel injector test stand ably demonstrates.

[Desert Rat Racer]’s test rig is designed to support four injectors at once and to test them under conditions as close as possible to what they’ll experience when installed. To that end, [Rat] mounted a junk intake manifold to a stand made from scrap wood and metal found by the side of the road. A pickle jar serves as a reservoir for the test fluid — he wisely used mineral spirits as a safer substitute for gasoline — and a scrap electric fuel pump pressurizes a junk fuel rail, which distributes fuel to the injectors under test.

For testing, the injectors are wired up to an electric injector tester, which is one of the few off-the-shelf components in the build. The fuel pump and injectors are powered by the 12 volt rail of a scrapped PC power supply. Just being able to watch the spray pattern is often enough to find a faulty injector, but in case a more quantitative test is indicated, each injector is positioned over a cheap glass cylinder to catch the test fluid, and scraps of a tape measure are used to measure the depth of the collected fluid. No fancy — and expensive — graduated cylinders required.

While we truly respect the hackiness of [Desert Rat Racer]’s build, the concept of avoiding buying tactical tools is foreign to us. We understand the logic of not dropping a ton on a single-use tool, but where’s the fancy blow-molded plastic case?

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Retrotechtacular: TVO

Hardware hackers come from a variety of backgrounds, but among us there remains a significant number whose taste for making things was forged through growing up in a farm environment. If that’s you then like me it’s probable that you’ll melt a little at the sight of an older tractor, and remember pretending to drive one like it at pre-school age, and then proudly driving it for real a few years later before you were smart enough to realise you’d been given the tedious job of repeatedly traversing a field at a slow speed in the blazing sun. For me those machines were Ford Majors and 5000s, Nuffields, the ubiquitous red Fergusons, and usually relegated to yard duty by the 1970s, the small grey Ferguson TE20s that are in many ways the ancestor of all modern tractors.

The Black Art Of Mixing Your Own Fuel

There was something odd about some of those grey Fergies in the 1970s, they didn’t run on diesel like their newer bretheren, nor did they run on petrol or gasoline like the family Austin. Instead they ran on an unexpected mixture of petrol and heating oil, which as far as a youthful me could figure out, was something of a black art to get right. I’d had my first encounter with Tractor Vapour Oil, or TVO, a curious interlude in the history of agricultural engineering. It brings together an obscure product of the petrochemical industry, a moment when diesel engine technology hadn’t quite caught up with the on-farm requirement, and a governmental lust for a lower-tax tractor fuel that couldn’t be illicitly used in a car.

TVO is a fuel with a low octane rating, where the octane rating is the resistance to ignition through compression alone. In chemical terms octane rating a product of how many volatile aromatic hydrocarbons are in the fuel, and to illustrate it your petrol/gasoline has an octane rating in the high 90s, diesel fuel has one close to zero, and TVO has a figure in the 50s. In practice this was achieved at the refinery by taking paraffin, or kerosene for Americans, a heavier fraction than petrol/gasoline, and adding some of those aromatic hydrocarbons to it. The result was a fuel on which a standard car engine wouldn’t run, but which would run on a specially low-compression engine with a normal spark ignition. This made it the perfect tax exempt fuel for farmers because it could only be used in tractors equipped with these engines, and thus in the years after WW2 a significant proportion of those Fergies and other tractors were equipped to run on it. Continue reading “Retrotechtacular: TVO”

Homebrew Gel Fuel Keeps The Steam Coming, Legally

All it takes is one knucklehead to go and do something stupid to screw things up for everyone. We’re not exactly sure who the knucklehead is behind the recent ban on hexamine fuel tablets, but given that it’s now proscribed in the UK under the “Control of Poisons and Explosives Precursors Regulations 2023,” we expect that that story is a doozy.

So what’s hexamine, and why should we care if it’s banned? As [Markus Bindhammer] explains, hexamine is a solid fuel commonly used to power model steam engines, among myriad other uses. Its ban leaves a bit of a hole in the model steam community, which [Markus] seeks to fill with this quick and easy gel fuel chemistry project.

The “California Snowball” is a homebrew version of what’s in those solid fuel cans you see heating chafing pans at catered events, with one common brand being Sterno. [Markus] used a saturated solution of calcium acetate (6 g in 50 ml of water) and added that to 150 ml of ethanol; commercial formulations usually use methanol to prevent anyone from drinking the stuff, with varying degrees of success. The calcium acetate forms a gel that looks like whipped cream and traps the ethanol inside. The gel can be easily scooped up and spread around, and burns with a clean, smokeless flame.

It may not exactly be a “plug and play” replacement for hexamine tablets, but one does what one can. And if there’s one thing we can celebrate about model steam engineers, it’s their persistence. We got a bunch of them together last year for a Hack Chat with [Quinn Dunki], and their passion for making things move with steam was pretty impressive.

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Who Needs Gasoline When You’ve Got Sodium?

YouTuber and serial debunker [Thunderf00t] was thinking about the use of sodium to counteract global warming. The theory is that sodium can be used as a fuel when combusted with air, producing a cloud of sodium hydroxide which apparently can have a cooling effect if enough of it is kicking around the upper atmosphere. The idea is to either use sodium directly as a fuel, or as a fuel additive, to increase the aerosol content of vehicle emissions and maybe reduce their impact a little.

One slight complication to using sodium as a fuel is that it’s solid at room temperature, so it would need to be either delivered as pellets or in liquid form. That’s not a major hurdle as the melting point is a smidge below 100 degrees Celsius and well within the operating region of an internal combustion engine, but you can imagine the impact of metal solidifying in your fuel system. Luckily, just like with solder eutectic mixes, sodium-potassium alloy happens to remain in liquid form at handleable temperatures and only has a slight tendency to spontaneously ignite. So that’s good.

Initial experiments using ultrasonic evaporators proved somewhat unsuccessful due to the alloy’s electrical conductivity and tendency to set everything on fire. The next attempt was using a standard automotive fuel injector from the petrol version of the Ford Fiesta. Using a suitable container, a three-way valve to allow the introduction of fuels, and an inert argon feed (preventing spontaneous combustion in the air), delivering the liquid metal fuel into the fuel injector seems straightforward enough.

[Thunderf00t] started with ethanol, then worked up to pentane before finally attempting to use the feisty sodium-potassium, once the bugs had been shaken out of the high-speed video setup. [Thunderf00t] does stress the importance of materials selection when handling this potential liquid metal fuel, since it apparently just bursts into flames in a violent manner on contact with incompatible materials. Heck, this stuff even reacts with PTFE, which is generally considered a very resistant material. We’re totally convinced we’d not like to see this stuff being pumped from a roadside gas station, at all, but it sure is a fun concept to think about.

Sodium-Potassium alloy doesn’t feature on these pages too often, but here’s a little fountain of the stuff, just because why not?

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Keeping An Eye On Heating Oil

Energy costs around the world are going up, whether it’s electricity, natural gas, or gasoline. This is leading to a lot of people looking for ways to decrease their energy use, especially heading into winter in the Northern Hemisphere. As the saying goes, you can’t manage what you can’t measure, so [Steve] has built this system around monitoring the fuel oil level for his home’s furnace.

Fuel oil is an antiquated way of heating, but it’s fairly common in certain parts of the world and involves a large storage tank typically in a home’s basement. Since the technology is so dated, it’s not straightforward to interact with these systems using anything modern. This fuel tank has a level gauge showing its current percentage full. A Raspberry Pi is set up nearby with a small camera module which monitors the gauge, and it runs OpenCV to determine the current fuel level and report its findings.

Since most fuel tanks are hidden in inconvenient locations, it makes checking in on the fuel level a breeze and helps avoid running out of fuel during cold snaps. [Steve] designed this project to be reproducible even if your fuel tank is different than his. You have other options beyond OpenCV as well; this fuel tank uses ultrasonic sensors to measure the fuel depth directly.

A Simple Stove, Built For Beans

Sitting around a campfire or fireplace is an aesthetically pleasing experience in most situations, and can even provide some warmth. But unless you have a modern wood-burning appliance, it’s likely that most of the energy available in the biomass is escaping as un-burned vapors. Surprisingly, solving this problem is almost as easy as buying a can of beans at the store, and the result is a very efficient stove which can be used for heat in a pinch.

[Robert] is demonstrating this gasifier stove, not with beans but using both a can of peas and a larger can of potatoes. Various holes are drilled in each can in a specific pattern, and then the smaller pea can is fitted inside the larger potato can. Once a fire is going, the holes allow for air to flow in a way which traps the escaping un-burned vapors from the fuel and burns them as they flow through the contraption. No moving parts are required; this is all powered by the natural airflow that’s produced by the heat of the fire.

The result of a build like this is not only a stove which can extract a much higher percentage of the available fuel, but also quires much less fuel for a given amount of heat, and produces a much cleaner, less smokey fire. [Robert] also added a screen mantle which allows for this to be used more as a heat source, but similar builds can also be used just as effectively for cooking, too.

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Powering A Cellphone With Gasoline

Batteries are a really useful way to store energy, but their energy density in regards to both weight and volume is disappointing. In these regards, they really can’t compete with fossil fuels. Thus, [bryan.lowder] decided to see if he could charge a phone with fossil fuels as safely and inoffensively as possible.

Obviously, with many national grids relying on fossil fuels for a large part of their generation, most of us are already charging our phones with fossil fuels to some degree. However, the aim here was to do so more directly, without incurring transmission losses from the long runs through the power grid. Continue reading “Powering A Cellphone With Gasoline”