GEK Wiki / Fabrication Instructions - GEK Version 3_5
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Fabrication Instructions - GEK Version 3_5

Page history last edited by jay 10 years, 6 months ago

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Fabrication Method and Standards


All GEK vessels are fabricated using the same three basic part types: vessel tubes, flange rings, and end plates.


The circular flange rings and end plates function as "jigs" to pull the vessel tubes to perfectly round for welding.  Tabs and slots on all vessels index the pieces together and ensure an accurate finished product.  This system of “self-jigging” is central to the ease of building the GEK.  Somewhat like snapping together a puzzle you were actually meant to solve.


While following the step-by-step instructions below, be sure to remember these other common standards across the kit.

- All flange rings and end plates should be oriented such that the slag side is down.

- All vessel tubes are rolled such that the slag side is facing inward

- All large vessel tubes will have approximately 3/8" overlap at the seam joint.  This makes welding much easier than welding sheet edge to edge.  The smaller vessels (cyclone and swirl burner) will have 1/4" overlap at the seam

- Tabs and slots will give you the correct positioning.  But do be careful to center the first tab and slot so the others will come out correct.  See notes in below text for details.

- When welding flange rings and end plates, start with short stitches around the circle.  Do not do one long continuous weld or you will warp the flange. 



The components must be built in the order presented below, as some parts have alignment needs with other parts.   



   1) v3.5 Gas Cowling and Rotary Grate



  2) v3.5 Downdraft Reactor  



  3) v3.5 Cyclone  4) v3.5 Filter   


  5) v3.5 Swirl Burner



  6) v3.5 Hopper



7) Paint it!



Once you have built all the components using the fabrication instructions above, use the Final Assembly Instructions to put it all together and prepare it for first fire.  Then use the How to Start and Run the GEK instructions to actually set the show in motion.  Please read these instructions.  They will save you many messy hassles.  Remember to always run your GEK outdoors, with good ventilation, and stay out of the smoke!


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