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mission:log:2012:07:17:motor-porn-honda-gx25-in-new-rig [2012-07-31 21:55] – typo fix chronomission:log:2012:07:17:motor-porn-honda-gx25-in-new-rig [2013-06-30 12:43] (current) – chrono
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 +====== Motor-Porn: Honda GX25 moved into new APU rig ======
  
 +What started out as a [[http://www.wohnmobilforum.de/w-t33081.html|simple thread]] on a mobile-home board, ended up in more than 50 pages of discussion about a neat and small generator project based on a Honda GX25 and a Torcman 430-30 brushless outrunner motor. Some people always seem to ask, why anyone would build something like that, if they could get more output power for less money from a ready made product? Because available products don't really match the requirements and why would anyone pay money for something one actually doesn't really want or need?
 +
 +Apollo-NG needs multiple independent energy sources to be able to function autonomously and independently from grid infrastructure. Although the basic requirements are supposed to be covered by alternative power technologies like solar and wind power, it never hurts to have a fallback for a rainy day. That's where the [[mission:tech:aquarius:apu]] comes into play:
 +
 +[{{:mission:tech:aquarius:honda-gx25-stripped-in-apu-frame1.jpg?640|Honda GX25 in new APU rig's frame}}]
 +
 +~~CL~~
 +===== =====
 +
 +However, it first started with this test setup to test the engine and the generator as a general prove-of-concept and to make sure that all parts were running satisfyingly, before taking them apart and reduce the whole thing to the max:
 +
 +[{{:mission:tech:aquarius:hond-gx25-torcman-430-generator-test-setup.jpg?640|Honda GX25 on the old test-stand}}]
 +
 +~~CL~~
 +
 +Last week, the extruded aluminum profiles for the rig arrived and were assembled by iggy, who seemed to like to play with LEGO for adult engineers. It seemed pretty easy, but maybe it's better if he'd care to comment on the ease and quality of the build. After stripping down the engine and removing all parts that were deemed //unwanted//, a big pile of spare parts piled up:
 +
 +[{{:mission:tech:aquarius:honda-gx25-stripped-parts.jpg?640|Removed parts from the basic Honda GX25 engine}}]
 +
 +~~CL~~
 +
 +When the engine is in the rig it's pretty easy to get a good imagination how things are going to look, when it's finished:
 +
 +[{{:mission:tech:aquarius:honda-gx25-stripped-in-apu-frame2.jpg?640|Honda GX25 in new APU rig's frame}}]
 +
 +~~CL~~
 +
 +[{{ :mission:tech:aquarius:apu-gx25-3-chamber-muffler.png?200|APU 3-chamber muffler design}}]
 +
 +The next task is to reduce sound emissions by creating a new muffler system. Research showed, that a simple 4:2:3 three chamber ratio in a body 20 times the volume of the engine (displacement) should provide good results and should have no effect on the output power of the engine. The preliminary draft design on the right basically shows the setup with the three chambers and the input (upper) and output (lower) pipes in a 90° angle.
 +
 +Luckily, Harald Zimmermann, who is somewhat of an expert on the topic, since he is [[http://www.zimmermannschalldaempfer.de/|designing and building mufflers]] for a long time, agreed to help out, by designing a muffler with good sound suppression and hopefully no noticeable engine power losses. Hopefully the [[mission:tech:aquarius:apu|APU]] will purr more quietly once the new muffler is ready and operational.
 +
 +~~CL~~
 +
 +<WRAP round tip>
 +If you are planning to build this too and have trouble getting the GX25 engine for a good price start thinking out of the box: These engines, when bought as a single unit, are nowhere available for under 300EUR, but you might want to look for Honda UMS425 motor trimmers - which basically have the exact same engine, this one used to be an UMS425 too :)  
 +</WRAP>
 +
 +{{tag>aquarius apu honda gx25 engine generator energy}}
 +
 +{{keywords>Apollo-NG apollo next generation hackerspace hacker space development makerspace fablab diy community open-resource open resource mobile hackbus aquarius apu honda gx25 engine generator energy}}
 +
 +~~DISCUSSION~~
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