How to build a Homemade DIY Geothermal Heat Exchanger to Cool Your Garage

    This project goes over the build of a Geothermal heat pump that takes the hot air in your garage and cool it down by transferring that heat into water .The cold water is pulled out of the ground through a shallow hand dug well and send to a heat exchanger inside the garage . A fan attached to the heat exchanger blows out the cold air into the garage . The heat exchanger absorbs the existing heat inside the garage . The warmed up water is then removed through an exhaust pipe.

    Just a few feet down the earth is a consistent 55 degrees, summer or winter. Water at that depth is about the same temperature. To harness the cold water down below, we dig a shallow well. To do this we use a post auger and a 3 foot long well point that is attached to a 10 foot three quarter inch pipe using a drive coupling. We start by digging a hole using the post auger till the water table is reached and then start driving using the well point for additional two to three feet until it is submerged under the water table.

    A two to three foot trench is dug from where the well is installed to the garage . A One inch poly pipe is connected to the well pipe using a barbed coupling and is buried inside the two foot trench all the way to a well jet pump .The trench is dug down at least two feet until you hit some hard pan clay that is about where the temperatures begins being more constant. This keeps the pipe cool under the earth.

    The other end of the poly pipe coming out from the trench is connected a 1/2 HP Flotec Shallow well jet pump . The pump can be powered by a solar panel. The pump is kept outside the garage as it generates a lot of heat. If it is kept inside the garage, cooling effect from the water will be undone by the heat generated by the pump.

    The output of the pump is connected to a three quarter inch copper pipe inside the garage. It is then further connected to a water pressure tank with the help of a brass tee and a union. A relief valve is also attached to the tee to empty the water tank if the pressure gets too high. A water pressure tank is used prevent the pump from failure .It also acts as a buffer storage.

    The other end of the brass tee is connected to two pipes. One pipe goes outside the garage to a faucet and the other pipe is connected to a radiator that acts as a finned tube heat exchanger.

    The heat exchanger captures the hot air surrounding the garage and stores the heat into the finned coils within the radiator .The heat is transferred to the water flowing through them . An exhaust line from the radiator carries this hot water to outside the garage.

    Two flexible hose pipes connects the input of the heat exchanger to the water tank and output to an exhaust pipe. A box fan is placed in the front of the radiator to blow the cool air . The fan can be powered by Solar panels. Once the water starts running through the radiator , we start the fan

    • DIY Video: How to build a really efficient Portable Multi Purpose Ammo Box Wood Stove
      This project goes into the build of an efficient portable ammo can wood stove that can warm your space, act as a cooking stove, baking oven and an alternative for ground fires at camp sites. This ammo stove is compact and doesn't take up additional storage . All the basic components used in this stove are modular and can be stored inside the stove when not in use. These components are easily available in your local hardware store. The basic components needed to build this stove are as follows. The ammo box called the "fat 50 "is purchased from an army surplus store for $30 , the titanium stove pipe for $100 , the metal for the control dial and the door is salvaged from old barbecues. Rest of the basic tools needed are grinder, blow torch, hack saw ,rivet gun and a drill press. Not only you can use wood logs, paper, twigs but it also runs on wood pellets. The system has a gravity fed hopper that feeds the pellets intermittently for consistent heat over a longer period of time. For maximizing the burn, a divided combustion chamber is used. This forces the burn to go around a sealed baffle before it exits out the stove pipe providing less smoke and retaining more heat. A thick steel plate is used as a cook top which is rescued from an old barbeque . This plate absorbs the heat for cooking and is removable thereby protecting the stove top. Additional feature is a baking oven underneath the stove. The first step to build is simply removing the lid of the ammo can stove which just slides of the hinges. Remove the rubber gasket on the back side of the lid using a plier . This rubber gasket is replaced using 3/8th inch stove rope. This provides heat resistant seal from smoke. Remove the handle by drilling along the spot welds on the sides of the handle just enough to weaken them and pull it using a screwdriver . Two holes of three inches are drilled at the top surface of the stove . These are done to fit in the titanium stove pipe and for the gravity fed hopper system. We use a three inch propane fuel cylinder tube to make a pipe collar as a guide to trace out the holes. These pipe collars acts as hopper support for gravity fed pellet mechanism and for securing the stove pipe. The hole for the first pipe is about five and half inches away from the door hinge and the second one , one and half inches away. The holes are then cut using a jigsaw. The flanges in the stove pipe collars are made by securing them against a wooden fixture and bent them using a hammer. The edges are heated with a torch to anneal the metal for hardening. Before inserting the stove collars into the lid, the metal sheet inside the lid was removed. Using fiber glass cloth, a smoke seal is made around the collars. The collars are then inserted and the metal sheet is reinstated with help of some stainless steel rivets. A adjustable damper is installed inside one of the collars .These damper provide control to both burning speed and fire intensity. Also the damper in a closed state also acts a base for a steamer or a boiler. The damper is made using a thin steel cut out of a disc , the size of the inside pipe diameter. The shaft from a barbeque skewer is inserted along slots drilled in the disc holding them underneath the collar. Inside the combustion chamber ,we have two dividers installed. One divides the combustion chamber and the bottom one separates the oven from the stove . The top divider acts as an inner wall . The combustion has to travel around the corner and then go outside through the stove pipe at the end. This collects more heat and has less smoke build up inside. The side door openings are four inches high and three and three eighth inches wide. The door is made out of thick steel plate which was salvaged from an old barbeque. The door has three holes for the air intake and it is supported by a regular door hinge. A small circle metal piece at the front regulates the amount of flow that goes into the stove. A secondary burn system is introduced inside the stove so that the air coming into the upper part of the combustion chamber where all the smokes ascends gets reignited . This drastically improves the efficiency of the stove. Here we use couple of half inch black iron pipe that is connected with 2 90 degree elbow and an end cap. Holes are drilled on the pipe so that the fresh air is introduced into the chamber. A hole at the side of the stove is made the air intake. The pipe is inserted into the chamber and secured in place using a coupling and a spacer. A 3 X 4 inch duct adapter is used as a funnel for the gravity fed hopper system. To make this efficient , we add a small cage made of door basket inside the chamber so that all the pellets wont drop suddenly to the bottom. The cage is made from the metal rods from the basket. The rods are spaced 8mm apart and put straps across both sides and secured it using rivets. To prevent the overflow of pellets inside the cage, a two and half inch tailpipe is placed at a specific distance below the hopper. This helps the pellet build up in the cage but not overflow. Now there is a sustained release of pellets at all time for a consistent burn. Stainless steel tent stakes are placed at the bottom of the stove riveted to a metal plate. This prevents the bottom from burning out and also improves air flow. Also acts as ash collector. To use this stove as a light source, we make a small window out of half mm natural mica glass. We use a fiberglass cloth to form a seal around window. It is held by green painters tape. After positioning the glass, spacers are added around the edge . These metal strips allow for the mica to expand and contract. Another metal frame is used to hold all these in place. The portable stove pipe is made out of titanium rolls. The titanium prevents corrosion and also distributes the heat efficiently. To make a long cylinder without denting the foil, unroll the film across the ground, roll it small enough to get the clips on ,spacing them evenly along the length of the pipe.
    • DIY Video:How to build a Simple Homemade Pocket Straw Style Water Filter. Small, lightweight and powerful.
      This project goes over the build of an emergency Straw Style Survival Water Filter. This water filter is small, lightweight and ideal for an SHTF scenario or hiking/camping. Very effective for purifying rain or tap water or removing disease causing water contaminants. With regular maintenance the filter should last for years. The materials needed to make this water filter are turkey baster , cotton balls, coffee filters,activated carbon. All these materials can be purchased from your local store or aquarium supply stores. The activated carbon is rated to last for five months if used regularly. Start by taking a cotton ball and push it down the turkey baster. Rinse the activated carbon by running it through tap water before putting them over the cotton balls. Pour the rinsed activated carbon all the way to the top of the pipe and put two more cotton balls at the top . Now take some coffee filter paper and slide it over the top of the cotton balls and tie it down using a twist tie or rubber band so that the whole thing wont slip out when you are using it. If you don't have the cotton balls available, you can always just ball up some pieces of coffee filter paper and put them on either end of the activated carbon in between. An alternative way of using this is to cut the top of the poultry baster and and put it on the top of the straw . Take the dirty water and manually filter it through the straw. Once the material inside the filter gets saturated water moves pretty thoroughly through the straw. The cotton balls in the paper will get dirty pretty quick up here capturing most of the dirt but you can just pull those out periodically and add new ones.
    • How to Recycle Old Used Laptop Batteries to make a DIY 24V 72AH Emergency Backup Battery System
      This project goes into the build of a 1.72kwh emergency backup battery system out of old and used laptop batteries and an old military surplus ammo box. The materials you need to build this project are lithium ion 18650 batteries from old laptops, 4X5,3X5 cell holders, ammo can, 40 Amp BMS or Battery management system, spot welder, fused nickel strip, heat shrink, kapton tape. First we determine how many batteries that we can pack inside the ammo box. In our case, we have 2 packs of 91 18650 cells , a total of 182 cells. We take the 4 X5 and 3 X 5 cell holders and connect them to make a couple of 7 x 13 cell holders. To make this 24V lithium ion battery , we need a 7S ( 7 cells in series connection) combination . A single lithium ion cell has a nominal voltage of 3.7V . To make a single long 7S configuration battery , we connect 7 groups of 26 cells in series to get the 25V nominal voltage. The cells used in the build are Samsung ICR18650 - 28A with a capacity of 2800Mah .The cells are rewrapped with heat shrink and added an insulator disk at the positive side of the cell for safety. The cells are installed on the holder in such a way that the first 26 cells are in a same polarity and are connected in parallel. Next 26 cells are installed with opposite polarity and is the connected in series with the first 26 cells . The rest of the cells are connected in the similar way to make a final 7S 2P ( 7 series and 2 Parallel ) configuration with max capacity of 26 X 2.8mah or 72.8 amp hours. A four wide fused nickel strip is used to connect the batteries in series. The nickel strip is placed over the first 4 cells and spot welded in place using the sunkko spot welder. Each cell is individually fused in case there is short circuit or malfunction. The nickel strip connects the first two rows in parallel and then connects the next two rows in series . Similarly, to complete the series connections, the nickel strips are placed and welded on the opposite side of the pack in such a way that it wont short out the connection by coming in contact with the most negative side of the battery. We take 0.15mm standard nickel strips to connect the positive ends of the whole pack together. The last 2 rows of most positive end are connected together using the nickel strip . Small pieces of nickel strips are placed across these two rows to connect them in parallel . The pieces are bent so that it can be connected to a separate copper busbar. The separate 2 battery pack of 7 X 13 cells are connected together by the nickel fuse strip in such a way that one of the pack is flipped on top of the other. The nickel strip that connects the first 3 connection on the 1st pack is bent to connect the 4th connection on the other pack. A 90 degree bent on the last row of the 4p fused nickel strip is welded on to the first battery pack. A piece of kapton tape is placed over the nickel strip to insulate it and hold it together. The bent nickel strip on the first pack is placed on the other pack is such a way that the fuses are perfectly aligned . Then it is welded using a spot welder. A one sixteenth inch ABS plastic is placed in between the two packs. The second pack is now slowly folded over the top of the first pack. The whole pack is then wrapped around with the kapton tape so that it doesn't move around. The last three unconnected terminals on one side of the battery pack is connected to the single row of unconnected terminal on the other side with help of four nickel strips. The 4p fused nickel strip is cut to connect the 3 sides and the other side. To connect the main negative and the positive tabs , we attach a THHN copper wire across the both the terminal ends. The extended nickel connections are folded across the wire to hold it into place and soldered . The terminal wires are then connected together with XT90 connector. Next step is to connect the BMS or Battery management system to the pack . This is a small circuit board which is used to protect each cells of the battery pack from overcharging and becoming unbalanced and getting damaged. It stop the over draining when the cells are fully charged. The BMS used here is a 7S 24V with charge current of 20A and discharge current of 40A. It has two negative leads, one connecting the battery and the other for charging and discharging. The BMS also has 8 sense or balancing wires which are connected to each series connections on the battery. The black wire is connected to the most negative terminal of the battery. The first red wire is connected to the first series connected group of cells, the second red wire is connected to the second series connected cells and so on. The last red wire is connected to the main positive terminal of the battery. A heat shrink is wrapped around the whole battery pack for added safety . Before inserting the battery pack into the ammo box, a hole is drilled on the back side of the ammo can to allow the cables from the battery to pass through. Also a small piece of one sixteenth inch ABS plastic is placed at the bottom of the ammo box as a support and insulation. The battery is slowly dropped into the box . The BMS is placed on the top and is connected to the XT90 connector and the balance wires from the battery. The B- terminal on the BMS is connected to the XT90 connector on the battery. The black wire on the BMS is the charge and discharge lead. To provide extra insulation between the battery pack and the the ammo box ,we attach two pieces of the insulting ABS sheet on either side of the box. The lid is put back on the box and the battery build is complete.