DIY GUIDE # 0003

MARK X: COMPACT
HYDROGEN REACTOR
STEP BY STEP DIY GUIDE

PART 1 OF 3: ELECTROLYZER 

✔ Detailed drawings with all sizes 

✔ List of parts and materials 
✔ Building Tips 
✔ AutoCAD files for laser cutting 
✔ Branded jokes that are not included in the video 
 

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Content
Content 2
Overview 3
Requirements for manufacturing. 3
Tools and equipment 4
Parts and materials 4

1. Manufacture of reactor parts. 5

1.1 Reactor geometry design. 5
1.2 Manufacturing of metal electrodes. 5
1.3 Manufacturing of hull walls. 6
1.4 Frame making. 6
1.5 Drilling holes in the frame. 7
1.6 Making grooves in the frame. 7
1.7 Cutting strips from the grid. 8
1.8 Assembling the filter from the strips. 8

2. Reactor assembly. 9
2.1 Assembly of reactors walls. 9
2.2 Pasting sealing gaskets. 9
2.3 Gluing the back plate. 10
2.4 Inserting the filter and gluing the front case. 10
2.5 Installation fitting and screws. 11
2.6 Seam soldering. 11
2.7 Checking the reactor tightness. 12
2.8. Electrolyzer refill. 12

4. Powering and switching on the electrolyzer. 13

5.About the developer. 14

   

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Overview
What it is?
Iron Man`s Mark X Compact Reactor - is a portable hydrogen
reactor designed by Alex Lab Researches. Just like Tony Stark
from the Infinity War had. A complete reactor kit is an
electrolyzer consisting of one pair of alectrodes, a backlight
with a decorative grid and a power circuit. This part of manual
is devoted to the most important part - the electrolyzer.

How it works?
This guy decomposes water and everything you decide to put
in it into the constituent gases through the process of
electrolysis. We all went through this at school, but mostly
past. The mixture of gases can be used as fuel for all kinds of
incendiary projects. This model, with proper assembly, can
withstand pressures up to 2 atmospheres and in the operating
mode produces a mixture of hydrogen and oxygen at a speed
of 100cc / min.

Requirements for manufacturing.

DIY production of a model requires skills in metal and plastic processing, drilling, cutting, soldering and gluing.
Accuracy of parts manufacturing and assembly allows for good tightness and reliable operation of the reactor.
During the assembly process, it is better to treat the reactor as a crystal one. Until it is completely glued and
sealed, it is quite fragile.

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Tools and equipment
Necessary Not necessary

● Knife and scissors ● LBM (if there is no laser and the plates
● Pencil and marker will be cut by yourself)
● Drill ● Drilling machine (for vertical drilling)
● File and file set ● Laser cutting machine
● Sandpaper ● Plexiglass cutting machine
● Clamps or clips 3 pcs. ● Dremel type multifunctional grinder
● M3 # 1 and # 2 tap
● Glue cinoacrylate (super glue) and plastic bag
● Rubber gloves
● Solvent (white spirit)
● Rags (better not fleecy and not mohry)
● Janet's syringe (150-200 cubes)
● Wooden stick for smearing glue
● Toothbrush
● Soldering iron with a round sting

Parts and materials

Material Quantity

Sheet of stainless steel AISI 304 ​110*85 2 pcs.

Plexiglass sheet 8 mm ​122*104 1 pcs.

Plexiglass sheet ​2 mm 122 * 104 2 pcs.

Alkali resistant rubber ​2mm. 5*5 2 pcs.

Pipe ​(stainless steel or copper) ø 4 mm 1 pcs.

Screws (cross or hex) M3 * 5 3pcs.

Silicone hose ø 6 mm 100 mm

Insulating tape 1 pcs.

Fum tape 1 pcs.

Plastic or metal plates ≈ 120 * 120 (for pressing parts at the time of gluing) 2 pcs.

Distilled water 30 ml

KOH (alkali / caustic potash) 20g.

Micron Stainless Steel Mesh 300*300 mm

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1. Manufacture of reactor parts.
1.1 Reactor geometry design1.
Build an equilateral triangle. Who has problems with
geometry, this is a triangle in which all sides and
angles are equal.
Build identical circles whose centers coincide with
the vertices of the triangle.
In my model of the reactor, I took a triangle with
sides of 160 mm as a basis and a circle with a radius
of 40 mm. Usually the size of reactor depends on the
required power. The dimensions of my model are set
so that it looks epic on the chest. Just show off. That
is why all subsequent sizes are not round, but
fractional.
If you are designing a reactor for your own chest, its
size may vary depending on your working weight
while press bench.

1.2 Manufacturing of metal electrodes.

Metal plates works as electrodes. It is important that
the metal is not destroyed in water and alkaline
solutions. Therefore, it is better to use stainless steel
AISI 304 or its analogues. Such steel is used in the
food industry and even Coca-Cola does not corrode
it. Details can be cut on a laser machine or made by
hand. The accuracy of the laser is higher, but it is not
always at hand.
If you cut with a laser, use pre-made Autocad files.
If you cut with angle grinders or hacksaws, use a
drawing.

✅ ​ ip: If you cut the part manually, it is better to

T
advance by 0.5 mm downwards. So it exactly fits into
place in the reactors frame.
Metal thickness 1 mm.
The number of parts is 2 pcs.

1
Dimensions on all drawings are in millimeters
​
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1.3 Manufacturing of hull walls.
Plexiglas parts can also be cut out by laser, or
manually. Depends on the level of technical progress
of your habitat.
When self-marking material, it is better to use the
principle of construction from paragraph 1.1.
By the way, if you want to make a reactor with a
working pressure of more than 2 atmospheres, take
a thicker plexiglas. The dimensions of all other parts
will be the same. In this model, 2 mm plexiglass is
used taken for compact installation. Well, to look
pathetic on the chest of course.
Plexiglas thickness 2 mm
Quantity 2 pcs.

 
✅ ​Tip: ​The number of parts in the list of
components is calculated per 1 reactor. If you cut
with a laser, order parts with a margin. It is not
always possible to manufacture the reactor from the
first time. Even my first two turned out to be
defective.

1.4 Frame making.

Cut a laser or manually frame. This is the most
important part of the reactor. All other parts will be
glued to it. It is important that the metal plates of the
electrodes freely stand in the inner part of the frame.
The filter from the grid will be inserted into the upper
rectangular compartment.
bath with electrodes and electrolyte will be In the
lower compartment.
Plexiglas thickness 8mm
Quantity 1 pcs.
And again about the spare parts. It is better to cut
parts with a margin. I thought that my hands really
grow from the right place, but I screwed up five
blanks. Everything goes well the first time only on
YouTube.

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1.5 Drilling holes in the frame.
After cutting the frame, make a system of holes in it.
Here are the diameters of the holes and their
purposes:

a. ​4 mm hole without thread. Drilled with M4 drill.

This is where the tube for the gas output is later
glued.
b.​The hole is drilled with a 2.5 mm drill and threaded
with a M3 tap. A screw plug is inserted into this hole.
c.​The hole is burned with a 3 mm screw, since the
drill does not creep in there. The gas passes from
the bath with electrodes to the filter through the holes
b.​and ​c.​After it the gas goes out through the hole ​
a.
d.​The hole is drilled with a drill 2.5 and the thread is
cut with a tap M3. Water is poured with a syringe
through this hole in the reactor, and the hole is
closed with a screw.
e.​The hole is drilled with a drill 2.5 and the thread is
cut with a tap M3. Water is drained through this hole

1.6 Making grooves in the frame.

After drilling is done, grooves are made for the leads
of the contacts of the electrodes. It is best to cut the
groove with a file with a rectangular section. Most
often, files are made just 5 mm wide, which
facilitates the work. Actually therefore ears of such
width.
One groove is made from the front side of the frame,
the second from the back side. Ideally, adjust the
depth of the grooves under 2.5-2.6 mm. Then the
contact between the body and the electrode using a
rubber gasket will be maximized.
Without gaskets, adjusting the depth of the groove
exactly to the thickness of the electrodes is much
more difficult.

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1.7 Cutting strips from the grid.
It is time to test your perseverance and accuracy.
Cut the strips of 74 * 10 mm out of micron stainless
mesh. It is better to make anticipation to the smaller
side and make strips half a millimeter narrower and
shorter. It is important that they easily get into the
compartment. I ruined the entire process of
assembling the reactor at the final gluing at the first
attempt, just because of one stri. So I had to do it all
over again.

✅ ​ ip: This mesh is used for making filters in water

T
wells. You can find it at the people involved in
relevant work.
Net thickness 0.1 mm.
The quantity is 20-25 pcs.

1.8 Assembling the filter from the strips.

20-25 chopped strips are collected in a pile. It is said
that in a Jedi Temple they gave out unlinges out of
turn for such work. It should make a stack of about
 
7.5 mm in height. For assembling strips, it is good to
use a compartment in a plexiglas frame, having
previously secured three strips of electrical tape in it.
Then the strips do not disperse and it is easier to
assemble the filter.
Bind strips with a tape. Yeah, yeah, I know, even the
reactor cannot be made without insulating tape.
It is important to assemble a filter of such thickness
that fits tightly into the compartment, but will not stick
out of it. Otherwise, it will not work to glue the case
with the plates.

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2. ​
Reactor assembly.
2.1 Assembly of reactors walls.

Glue the electrodes to the plates of the housing.

Not to miss, you can mark the plexiglass plate with a
marker. You can also put the frame under the case
plate and orient along it.
So you need to glue the front and rear walls. It is
necessary to glue it in such a way that, being located
by the electrodes inwards, and by plexiglas
outwards, the leads of the electrodes with holes
would look in different directions.
The leads of the electrodes will also function as
brackets. The reactor will be suspended for them on
the chest like an amulet.

Important! The tightness of reactor depends on the

accuracy of gluing. If even a square millimeter is not
glued, there is a chance of leakage. Do all the gluing
steps slowly and carefully. Before gluing process all
the surfaces. Remove dust with a toothbrush, then
degrease with a solvent. Prayer before the operation
is also a good idea.

2.2 Pasting sealing gaskets.

Cut out from 2 mm rubber square pads 5 * 5 mm and
paste them into the grooves cut in the frame. Without
such rubber bands, the reactor will leak.
Before gluing, the gasket must also be degreased.

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2.3 Gluing the back plate.
Glue the back plate of the case to the frame. it is
necessary to glue the places near the gaskets
carefully.
It is not necessary to wait for the full drying time of
the glue in this step. It is better to do the following
operation 2.4 and clamp the reactor with clamps
when both walls are in place and the filter is inside.
Have you ever read the instructions on the glue
package before taking the package? Remember the
words: “the decisive factor is the force of
compression, and not its time”. So be sure to glue all
the parts with clamps.

2.4 Inserting the filter and gluing the front case.

Carefully insert the filter into the upper compartment.
The grid should absorb a little pressing.
Check whether the filter is compacted so that it can
be closed by the front plate. If not, then you can
remove a couple of strips from the filter, removing
the duct tape in turn.
Important! Glue the front plate of the case to the
frame. This is a very crucial stage. If all previous
operations were done neatly, then the plate will snap
into place like a glove. Make sure that all parts are
sewn as it should, and that the frame does not catch
on the metal. There should be no gaps.

Now the reactor can be squeezed with clamps

Even if the “Second glue” is written on the glue, we
leave the reactor under the pressure to glue for 12
hours at least.

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2.5 Installation fitting and screws.
Tighten the M3 screws with a length of 5 mm into the
holes ​b. d. e. It is more convenient if it is hexagon
screws.
A piece of stainless or copper tube ø 4 mm and
length 15 mm is glued in in the hole ​a. We will
connect a flexible hose for the gas output to this
tube. All screws must be sealed with fum tape for
better tightness.

2.6 Seam soldering.

After the glue has completely dried, solder all the
seams with a soldering iron with a round sting. This
further enhances the tightness of the reactor.
Carefully solder the places near the outgoing
electrodes. If the tightness of the reactor is broken,
most often it happens in these places.
The technical tasks for this model did not include the
need to withstand high pressure. But if there is a gas
leak, the reactor will not normally inject gas into such
things as a repulsor or a mini-rocket launcher.

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2.7 ​Checking the reactor tightness​
.
Check the reactor for leaks using a medical syringe.
Best suited is Zane`s syringe on 150-200 cubes.
Tighten all screws tightly, connect a syringe with
recirculated air to the fitting. Press on the plunger of
the syringe with moderate force. If the reactor is
assembled qualitatively, the air should not go out.
You can also check the model for tightness by
dropping it into the water.

Important! Do not push the piston too hard. The

walls of the reactor will not stand and bend, we will
break the tightness of the structure.
If the tightness is broken in straight lines of the
seams, you can try again to solder these places. If
air leaks near the electrodes, then most likely you
will have to make a new reactor. It was this advice
that I followed the first couple of times.

2.8. Electrolyzer refill.

The reactor can be filled with any liquid, at least
partially consisting of hydrogen and oxygen. You
understand who will survive in a zombie apocalypse,
right? Tap water, river, sea, alkali solution, or
compote from your granny. The most effective gas
yield is obtained from a 15% solution of alkali with
distillate. KOH, alkali, potash or caustic potash, as it
is called, is sold in a chemical reagent store or lies in
a chemistry laboratory class. You can pull out from
there.

To refuel reactor, unscrew the charging screw from

the hole ​d.​, And pour liquid into the reactor using a
syringe with a needle. Replace the screw; make sure
that all screw connections are tight.
To drain the electrolyte from the system, unscrew the
screw e. It is rarely needed in general,. The last time
I twisted it out, was when my bright head thought to
pour Fanta into the reacto. Just for fun.

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4. ​
Powering and switching on the electrolyzer.

The Mark X reactor was designed to be powered by a 18650

lithium-ion battery with a voltage of about 4 volts. To make sure that
the model is working, one can is enough.
Connect the battery contacts to the terminals of the reactor.
Connection polarity does not matter.
When an electric current is passed through water, the water molecule
is decomposed into its constituent gases: hydrogen and oxygen. Gas,
which is called Brown's Gas, Thunderbolt or Hydroxy. The burning
temperature of gas is more than 2000 degrees Celsius.
The average gas release rate with washing from 1 lithium-ion jar with
15% KOH solution is 100cc / min.

The reactor can also be powered from any power supply, including
laboratory and phone adapters. The optimal supply voltage is 2-4
volts, with a current starts of 2 amps.
If the operating voltage is exceeded, the reactor will quickly overheat.
Assembling the power supply with a belt clip for portable carrying will
be described in Part 3 of the instructions.

The release of the following instructions is assigned after the Avengers

Finale. In Part 2 we will do the backlight for the reactor. And so that it
looked just like in the movie! An optional node, but what kind of a
reactor is it if it doesn't glow, right?

Disclaimer # 1. The reactor produces gas with the highest rate of ignition in the Universe. It

⚠ doesn`t matter Marvel or DC. This is not a joke. The speed of Brown’s gas blast wave propagation
is 2800 m/s. Never ignite the gas coming out of the reactor directly without safety valves! The
flames will suck in and the reactor will burst on the chest before you can say “Whatever it takes”. I
checked it. Avoid sparks and open flames near the reactor.

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5.​
About the developer.

Alex Burkan is developer of this and other interesting models.

Inventor, engineer and Alex Lab Researches founder.
Alex is engaged in research of hydrogen technologies, develops own
power stations and popularizes science.
According to his most loyal fans, earlier the word electrolyzer was
mentioned in the world only in boring lessons at school.
To everyone's joy, the designer is an ardent fan of science fiction, a
fan of Star Wars and the Universe Marvel, and loves to have fun with
his own inventions.
The most spectacular frenzy can be observed on his channel.
http://youtube.com/alexlab

Disclaimer # 2.​Never transfer this file to anybody and do not post it in free access!

⚠ Firstly, honestly paying for access, you are tremendously helping to make new developments with
much greater speed. And I really appreciate it.
Secondly, you know that the illegal distribution of intellectual property is prosecuted under law. The
laws and implies unpleasant sanctions up to the real term. Distributors are found out by IP-address
during the day, regardless of the encryption system and browser used.
Othermore, I will lie for a week in deep depression again if I see an unlicensed copy of the
instruction. And who needs it.
Please respect the work of the author and do not be silly.

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