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How to Create Brown Gas Using Battery Housing

Brown's Gas, or HHO as it is commonly called, is the result of electrolysis using mineralized water. Casings used for a small electrolysis chamber vary, but they are typically thick ABS plastic cases that have been recycled from other uses. Car batteries have durable, acid-proof, insulated cases that are ideal for making HHO generators. These cases can be emptied of their electrolyte and plates, cleaned and fitted with an electrolysis reactor. The cases are also heat resistant, and can withstand temperature extremes. The average HHO experimenter can build an HHO generator out of a battery case in about an hour.

Things You'll Need

Empty battery casing
Ammonia-based cleaner (Windex or multipurpose)
Lint-free towel
HHO reactor plate assembly (assembled)
Fuel hose (several feet)
Hose clamps
1/4-inch pipe elbows
Rubber mallet
RTV silicone
Distilled water
Baking soda
Heavy gauge wire (>14 gauge)
Drill
Screwdrivers
Socket set
Pliers
Electrical tape

Instructions

- 1
  Clean the interior of the battery casing and lid thoroughly with an ammonia-based cleaner, and rinse completely with clean water. Dry with the towel and allow the casing to air dry. Removing any residual battery acid or deposits is important for the proper functioning of the HHO reactor.
- 2
  Mount the HHO plates into the underside of the battery casing lid. Drill two holes for the plate assembly post bolts and push them through from the bottom of the lid. Secure the posts with nuts, turning them clockwise until they are tight. Mark the positive post bolt with a small strip of electrical tape.
- 3
  Drill a hole for air intake, and one for HHO output into the lid. The holes should be evenly spaced and at opposite ends of the casing. Spread a liberal amount of RTV silicone around the larger end of each pipe elbow. Press a pipe elbow into the top of each hole, lightly tapping it into place with the rubber mallet. Most pipe elbows are made of plastic, and may break if rapped too hard. Face the elbows in the proper direction (leading to air intake in vehicle when mounted), and allow the RTV to air dry for 15 minutes.
- 4
  Fill the battery case to two-thirds full with distilled water and add 1/2 tablespoon of baking soda. Mix the baking soda with the water completely, stirring until it dissolves.
- 5
  Mount the lid with the attached HHO generator assembly into the battery casing by lowering it into place and pressing the lid to the case.
- 6
  Attach the fuel line to the elbows and secure with hose clamps, turned clockwise until they are tight. The fuel line length is determined by the application, but normally it is around 3 feet for each elbow.
- 7
  Attach two sections of wire, one to each HHO plate post bolt. Wrap a stripped section of wire around the bolt and lock it in place with a nut turned clockwise. The nut will pinch the wire and create a stable connection. The wire should be the length necessary to provide power, and should include the switches and relays required for a safe circuit. For testing purposes, uninterrupted wire connected directly to a battery will suffice. Once connected, the power from the battery will cause electrolysis to begin inside the reaction chamber. With one fuel line connected to a load, and the other left open, a continuous stream of HHO will be generated.

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