Charcoal Stove: Final Sheet Metal Test Model

ASSEMBLING THE FINAL MODEL! 

(Figure 1- Measuring and cutting)

Our final model was in many ways similar to our initial cardboard sketch model. We were able to carry over almost all of the design concepts that we initially laid out, such as the interior door that divided the fuel compartment into two section, as well as the fuel drawer; however we did make some alterations to the construction and assembly of the stove. The material was far more difficult to work with than the cardboard. It was extremely sharp and difficult to cut, form and bend. (I was wounded during the process of building the stove- BATTLE SCARS! See Figure 2 and 3) Such changes in the material pushed us to make some alterations. We tried to simplify the construction as much as possible; limiting the number of pieces used, and creating single piece construction when we could. For the base rectangular frame of the cooktop, we used a single piece of sheet metal. From the single sheet we bent it into a four sided rectangular tube. We cut the doors and the feet from the single sheet of metal. We also cut an opening on the bottom of the rectangular tube- the opening was just under where the fuel would sit - thus allowing oxygen to enter the compartment directly. On the edges of the tube, we left room to create small flaps that would allow us to bracket the side pieces onto the tube. 

(Figure 2 - Battle Wounds!)

(Figure 3 - Battle Wounds Up Close) 

The process of bracketing the metal together was also far more difficult than we had initially thought. We had difficulty making the holes in the metal the right size. The drill would often cause the metal to pop back up with it, making the holes bigger. We ran into great difficulty bracketing the sides of the stove to the main body because 1.) the metal was very flexible and bend under the pressure of the drill, 2.) the overlap of material was really small, and difficult to control. We found that instead of using the fixed drill, the hand held drill was far easier to maneuver. The hand held drill allowed for far greater control and flexibility. Katie was thus able to drill the hole while I held up the metal by placing my hand on the inside of the stove through what would later become the air vents under the fuel drawer. 

Figure 4- The finished base of the stove-
With the fuel cutouts and legs.

(Figure 5- Cutting out
what will the feet on the stove) 

One of the most difficult tasks was the construction of the chimney. Luisa developed a multi-piece chimney; however we later decided to simplify the chimney into a single tube. Using a long sheet of metal, we rolled it, and bracketed it. We wanted to metal to far enough away from those using the cook stove which would be close to the ground. (When we rolled up the material into its tubular form, we found it rather difficult to control the size of the bracket holes, and needed to resort to using bolts and screws that would fit the larger holes.) After making the tubular form, we made an angular cut at the base of the chimney. We made a simple cut up the chimney about 4 inches, and then bent the material back. We cut a hole in the back of the stove, and place the chimney over the whole. The bent wings on the chimney were used to bracket the chimney to the back side of the stove. 

Below are more pictures: 

Drawer Construction: 

The fuel drawer is almost built! 

Katie with the single sheet cutout that would later
become the fuel drawer! 

The completed fuel drawer with Charcoal in it!
TESTING DAY! 

Chimney Construction Process Photos: 

Taping the tube of sheet metal together
in order to keep everything in place

The bracketed tube! 

Bracketing the chimney 

The Final Product :              

Pulling out the fuel 

Putting on the chimney

The side of the cookstove, after we
successfully bracketed it together!

The Final Model of of the Stove