(word processor parameters LM=8, RM=75, TM=2, BM=2) Taken from KeelyNet BBS (214) 324-3501 Sponsored by Vangard Sciences PO BOX 1031 Mesquite, TX 75150 There are ABSOLUTELY NO RESTRICTIONS on duplicating, publishing or distributing the files on KeelyNet except where noted! March 28, 1992 GFILTER.ASC -------------------------------------------------------------------- This file shared with KeelyNet courtesy of John Draper. -------------------------------------------------------------------- VEHICLE GASOLINE FUEL PURIFIER Remove the impurities that the refineries leave in .... Clean burn gasoline promotes: o Better Combustion o More Power o Better Mileage o Cleaner Emissions WARNING !! - This project involves cutting gasoline fuel lines, and is NOT recommended to those who do not feel comfortable cutting fuel lines, making leak proof connections and working with a volatile substance. This project was one of the most interesting, that I have ever done. I wish I had more experience in chemistry so that the results could be tailored as desired. What we are doing, is making a charcoal filter and installing it in the fuel line. The particular type of charcoal used, removes the paraffins and varnishes from the gasoline, thus making it burn faster and more completely. The filter is installed between the carburetor and fuel pump on carburated cars. I have never used one with fuel injection, however there is no reason not to, if one understands the fuel pressures generated by the fuel pump, and designs this project with that in mind. The information about this project, was obtained from a retired petroleum engineer, who worked for a refinery in Tulsa, Oklahoma for 25 years. Refineries, refine gasoline just enough to meet what government regulations require, and no more. This is done as a matter of cost. Higher grade fuels for aircraft and other high performance requirements, are also made, but at a significantly higher cost, because of the additional refining required. Page 1 Cracking or the refining process for crude oil, uses heat to derive the many products, including gasoline products. There is another way of separating the various elements, purely mechanical, using the properties of activated charcoal. One pound of activated charcoal, has the equivalent of 6.4 acres of surface area. Passing the gasoline through charcoal, larger molecules of paraffin and varnishes, are trapped in the charcoal, allowing only the smaller, lighter hydrocarbons to pass through. The activated charcoal used in the construction of this project is a coconut based charcoal, which has the particular properties that we are looking for. Dry cleaning establishments use coconut charcoal as one of the methods they use to keep their dry cleaning fluid clean, so they don't have to change it so often. Construction Details The construction of the charcoal filter uses sealed, PVC pipe and end caps. The filter can be made up of steel pipe, using the same dimensions and sizes described. The filter will be effective approximately for 2500 to 3000 miles before the charcoal becomes saturated with impurities and loses its ability to trap the paraffins and varnishes. When the filter has become saturated with paraffins and varnishes, the filter will not stop gasoline flow, however. You will notice that performance is not what it had previously been. It is recommended that the very first filter be built using the PVC pipe. If you are satisfied with the results, consider building one out of steel pipe and threaded end caps, so that the charcoal cartridge may be replaced, at the same time you change your oil. Material Requirements: 1 pound of activated coconut charcoal. 12X30 Mesh. (1 lb. of charcoal will make 2 filters) May be obtained from: Barnaby & Sutcliffe Corp. 835 N. Cassady Avenue P.O. Box 2526 Columbus, Ohio 43216 Telephone: 614-258-9501 Barnaby & Sutcliffe's Part No. PC 1354. 1 Piece 2-1/2 inch, O.D. X 7 inch long PVC or ABS Plastic pipe. 2 Pieces 2-1/2 inch, End Caps PVC or ABS Material 2 Brass Fittings, 1/8 Male pipe thread to 5/16 inch compression type. Page 2 1 Womens knee high or panty hose style Nylon stocking. (Used to contain the charcoal catalyst material) 1 Can of PVC or ABS Bonding Adhesive 1 Can or Bottle of Plastic Cleaner. Length of 5/16 gas line hose. Standard, replaceable fuel line filter to be installed before the carburetor or injectors, to catch any loose charcoal particles. Worm gear clamps. ASSEMBLY INSTRUCTION Take the 7 inch sleeve, check ends for burrs and uneven spots after cutting, and smooth them out. Then set the sleeve on work bench to prepare for packing the charcoal catalyst. Take the NYLON panty hose (one of the legs), check and make sure that there are no holes or runners. The Nylon hose, is an inexpensive method to contain the catalyst bed. Tie a knot in one end of the nylon hose, and cut off the excess. Then insert the tied end, into the top opening of the PVC sleeve, until it touches the bottom. Allow 4 or 5 inches of nylon hose to protrude above the top of the PVC sleeve. (This creates a funnel effect) Then take the catalyst carbon material using a paper cup as a scoop, pour the carbon catalyst into the nylon hose. It may be necessary to use a funnel if your hand isn't steady. Fill the nylon hose carefully, making sure that the carbon catalyst is spreading out evenly within the sleeve. Tapping on the sleeve body with a screw driver or similar tool while filling, will help the carbon catalyst settle and pack. After the sock is completely full, draw the loose end and tie a knot in it as close and tight as possible. Cut off the surplus. Be careful not to puncture the nylon material. Take two pieces of light gauge steel band (the type that is used for strapping of wooden crates) 3/8 inch width, cut square 1/16 inch longer than the inside width of the PVC sleeve. (These are used as the carbon catalyst bed, retainers). After cutting the bands to size, wrap them with plastic electrical tape. Insert one strip into each end of the PVC sleeve on a angle, and force them against the tied nylon hose ends within the PVC sleeve. These bands will lock into place holding with their sharp corners and retain the carbon catalyst bed from shifting. The steel bands should bow-inward, toward the middle of the sleeve. The PVC sleeve is now a complete cartridge ready for the final assembly. Drill a 5/16 inch hole in the center of both end caps. Using a 1/8 inch pipe tap, thread each cap from outer surface to only half length of the tap, to allow for a tight fit. (This procedure applies only when using PVC or plastic material). Use a plastic cleaner and a clean rag, wipe both ends of the sleeve and the inner rim of the end caps, making sure they are clean. Allow the area to dry. Apply bonding cement to the inner sides of Page 3 the end caps and sleeve ends. Slip the end caps over the ends of the sleeve and rotate while forcing the unit together. Allow to dry for two hours. Assemble the brass fittings to the threaded end caps using a pipe thread compound. Cut two pieces of 5/16 inch copper tubing 3 inches long, and insert one in each brass fitting and tighten. Neoprene fuel lines can now be attached to the filter. (For fuel injected engines - Make sure that the hose you use, can withstand the pressures of the fuel pump - Don't skimp!) Mounting Instructions: The filter should be mounted vertically, with the input hose from the fuel pump, going into the TOP of the filter. Mount the unit under the hood of the vehicle, preferably in the space between the radiator and the front grill. If no space is available there, mount it in the engine compartment away from the exhaust manifolds. Most installation made in the engine compartment are mounted on wall of the inside fender area. A simple bracket can be made for mounting, using an ordinary worm gear hose clamp around the sleeve body. NOTE : When gasoline goes into the unit for the first time, the filter becomes hot, because of the catalytic reaction of the gasoline and charcoal. After a moment, the purifier will become cool, and will remain so thereafter. For people who need a racing fuel: Build the filter as described, but with the following exceptions: You can make your own racing fuel by making the filter 24 inches long, and manually pouring untreated gasoline through it, catching the treated fuel in a gasoline container. You can make just enough fuel you will need for race day. I suggest that you make a floor stand for the filter, with a funnel arrangement at the top. The longer length will provide much more filtering, providing a very volatile fuel. Of course, this will require more charcoal in the making of the filter. Be sure that you install a standard fuel filter to catch any loose charcoal particles. I like using the paper type element, fuel filters. BE SAFE.....DOUBLE CHECK ALL CONNECTIONS AND FITTINGS FOR LEAKS. -------------------------------------------------------------------- If you have comments or other information relating to such topics as this paper covers, please upload to KeelyNet or send to the Vangard Sciences address as listed on the first page. Thank you for your consideration, interest and support. Jerry W. Decker.........Ron Barker...........Chuck Henderson Vangard Sciences/KeelyNet -------------------------------------------------------------------- If we can be of service, you may contact Jerry at (214) 324-8741 or Ron at (214) 242-9346 -------------------------------------------------------------------- Page 4