Evening!
Busy night and day so far. Robbed the lean fir loggie (last page) of his ss heater cover to lazily avoid having to cut a new one for the second mahogany-sapele unit, I did a high mass core (HMC) for some days ago
Looking down on the naked resistor in the sad fir twiggy now, I realized that I hadn't experimented with a proper glass core since I gave up on bamboo a few month ago. So I made it a neat glass core set into a cork base
With the high glass tolerances though (core is somewhat between 10 mm and 10,5 mm, I'd guess), I still haven't found any suitable glass stems or tips for it, to slide over and provide a good enough seal. Arizer glass being about 1/2 mm too wide, my DIY glass stems being to narrow. O-ring for sealing on the cover itself won't work, as the heater sits too high up for even a high temp o-ring. Reeks!
So I made a simple all wooden stem for it (wooden bowl and all), from a 14mm beech round rod. Works quite well so far and we'll see, what we can find in the future re fitting glass tips/stems
For the new lean mahogany bodies (4 cm x 9,5 cm), I redesigned the High Mass Core (HMC), I experimented with in the last weeks, realizing that I fell into the same trap of mistaking it's size by working from pics again! Filling a 30 mm or even 40 mm bore with 30 mm OD flat ss washers, each 3 mm thick! WTF was I thinking!?
The whole HeavyMetalMonster maple prototype weight nearly half a pound then and no wonder I needed the more powerful 10w cartridge heater in there then.
Hell, it all looks so big on the pics, when there's no real point of comparison in the background somewhere
Then, after seeing that even a 30 mm bore in the lean mahogany bodies would leave only a 5 mm wooden shell, which might be a bit on the thin side for a massive and super hot ss cylinder in there, I went with the 25 mm bore I had used for most of my MistyPine prototypes up until now... and lo and behold, all of a sudden my problems finding extra wide 30+ mm washers with a fitting inner diameter around 9-12 mm vanished into thin air and I had a shitload of perfectly fitting 15-25 mm flat-, star- and lock-washers already at hand in the multi part washer sets, I had bought before
Also: Jumping back to
@Alan 's
The HI Thread with the pic of his collection of different log heater/cores, I finally noticed the resistor placed in front of all the cores as a size reference, being itself only about 20 mm long. Though he clearly states most of the cores having a 3/4" (about 2 cm) outer ss tube, the use of inches instead of centimetres still fails to instantly provide me with a sense for size when I read infos like that
The new High Mass Core is only of about 20 mm width and 40 mm hight now, with the 9 mm OD heater tube and port extending up to 60 mm in hight. Approximate weight is about the same, as a 18650 li-ion cell (no scales! Ruler and an 18650 as counterweight had to do), i.e. ~45g (the standard 60 mm x 9 mm x 0,3 mm heater tube/cover is about 5g only). It's powered by the 7w heater cartridge now (24v/30w Reprap cartridge. Applying 1/2 the voltage = 1/4 of the wattage output), like I initially intended.
There are fourteen flat 15 mm (OD) M10 ss washers interspaced with four ss 18 mm star lock washers, which increase surface area due to their fins/claws and also provide air intake around the sides of the core, so that air can enter into the slits at the bottom of the center tube. At its top is a single regular external star washer of about the same size, providing air intake from the top. On top of that, goes a single 25 mm (OD) flat washer with a wider inner diameter, to close up the core
* - held in place with a fitting No. 25 internal clip ring. Center heater tube is flared out at the bottom, with one of the 15 mm M10 flat ss washers held by the flare and another big 25 mm flat washer sits on top of that, to provide the bottom part of the core/heat exchanger (for now it’s still held by an additional teflon washer, but that will get replaced by an M10 or M12 internal ss star spring lock washer, through the gaps of which the screws for holding the cover should fit).
Whole core is surrounded not by another massive and solid outer ss tube like in the classic first generation logs (PD, AZ/MZ/CRZ etc.), but just a sheet of rolled up 0,3 mm thick ss foil/sheet, with its ends overlapping (cut up on the pics to show the interior). The idea behind that is to avoid possible wood charring by the more massive core by reducing material thickness of the outer ss tube in direct contact with the wood and thereby actually lowering thermal resistance and increasing heat transfer/conduction to the wooden body and from there finally dissipating it to the surroundings by convection, as... "The lower the thermal resistance, the better the heat sink, because it can dissipate the same heat output with a smaller temperature difference. As a result, the component remains cooler, which benefits the life and reliability.” Remains to be seen though, if I got that right… not exactly being Mr. Physics myself here, but just hopping from source to source absorbing that fraction of information, that I’m able to grasp as a layman there
I.e., if I got that right, a thicker, more massive outer ss tube in direct contact with the wood has higher thermal resistance and lower conductance but also is less ideal or counter productive, when you want to get rid of excess heat and so working as an actual heat sink, instead of just maintaining the state of a system, where you want more thermal resistance and less conduction.
Anyway, the new High Mass Core will be an optional core, that’ll come with the units I plan to offer besides the Standard lightweight ss heater cover.
Last but not least I improved the multi tip size bushing of the heater port by adding a clip ring and an optional high temp silicone O-Ring (sits far enough away from the heater itself now near the top of the bushing), supported by a the dimple, serving as a stop, hinderiung the bushing to slide down the cover, which now allows for even better sealing of the Arizer Air/Solo glass stems and GonGs. Seals also with bigger sized glass, like an 18 mm male tapered ground glass joint
Cheers
* (and to get that out of the way beforehand... this is definitively not a 'closed core' in the sense, that the UD's maker, Dave, uses the term, i.e. sealed and airtight in all parts, apart from the top intake... but merely in the sense that a stack of washers fills up the center bore of the wooden body for increased thermal mass and heat capacity, together with an additional outer ss sleeve around the whole contraption to form a more complex heat exchanger, and thereby 'closing' it up and insulating the center tube, in comparison to an 'open core', where you just have the central heater tube left (or cover), which is then insulated only by the narrow air gap, between itself and the surrounding wooden sleeve. This is how I found those terms used by folks in several online discussions and reviews, before I read Dave's interpretation. To spare us all confusion, I'll refer here to the 'Standard Core/SC' (i.e. just the ss heater cover + air gap for insulation, like in Alan's HI/TT) and to the 'High Mass Core/HMC' (i.e. stack of ss washers added around the center heater tube/cover, to increase thermal mass, much like in the old PD, AZ/MZ and so on)