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How I Built a 5 HP Stirling Engine from Scratch: A Step-by-Step Guide

Have you ever wondered how to build your own Stirling engine? A Stirling engine is a type of heat engine that converts heat into mechanical work. It can run on any heat source, such as solar, biomass, or waste heat. It is also very efficient, quiet, and environmentally friendly.

In this article, I will show you how I built a 5 HP Stirling engine from scratch using common materials and tools. I will also share with you the challenges and solutions I encountered along the way. By the end of this article, you will have a clear idea of how to build your own Stirling engine and enjoy its benefits.

What is a Stirling Engine?

A Stirling engine is a heat engine that operates by cyclic compression and expansion of air or other gas (the working fluid) at different temperature levels. The heat energy is transferred from a hot source to a cold sink through the working fluid. The working fluid is contained in a sealed system and does not leave the engine.

A Stirling engine consists of four main components: a hot cylinder, a cold cylinder, a regenerator, and a displacer. The hot cylinder is in contact with the heat source and the cold cylinder is in contact with the heat sink. The regenerator is a device that stores and releases heat between the hot and cold cylinders. The displacer is a piston that moves the working fluid between the hot and cold cylinders.

A Stirling engine works in four phases:

  1. Heating: The displacer moves the working fluid from the cold cylinder to the hot cylinder. The working fluid absorbs heat from the hot cylinder and expands.
  2. Expansion: The expanding working fluid pushes the power piston in the hot cylinder and does work on the flywheel.
  3. Cooling: The displacer moves the working fluid from the hot cylinder to the cold cylinder. The working fluid releases heat to the cold cylinder and contracts.
  4. Compression: The contracting working fluid pulls the power piston in the cold cylinder and does work on the flywheel.

The cycle repeats itself as long as there is a temperature difference between the hot and cold cylinders.

How I Built a 5 HP Stirling Engine from Scratch

I decided to build a 5 HP Stirling engine from scratch because I wanted to challenge myself and learn something new. I also wanted to have a reliable and sustainable power source for my home and workshop. I did some research online and found some plans and tutorials for building Stirling engines. However, none of them matched my specifications and budget. So I decided to design and build my own Stirling engine based on some basic principles and concepts.

Here are the steps I followed to build my 5 HP Stirling engine from scratch:

  1. Gather the materials and tools: I used mostly scrap metal and wood for my Stirling engine. I also bought some parts online, such as bearings, seals, valves, and springs. The total cost of my project was about $300. The tools I used included a drill press, a lathe, a welder, a grinder, a hacksaw, a hammer, a screwdriver, a wrench, and a ruler.
  2. Build the hot cylinder: I used an old propane tank as the hot cylinder. I cut off one end of the tank and welded it to a steel plate. I drilled two holes on opposite sides of the tank for the power piston rod and the displacer rod. I also drilled four holes on top of the tank for mounting the regenerator.
  3. Build the cold cylinder: I used an old fire extinguisher as the cold cylinder. I cut off one end of the extinguisher and welded it to another steel plate. I drilled two holes on opposite sides of the extinguisher for the power piston rod and the displacer rod. I also drilled four holes on top of the extinguisher for mounting

  4. Build the regenerator: I used a steel mesh as the regenerator. I cut it into four pieces and bent them into U-shapes. I inserted them into the holes on top of the hot and cold cylinders and secured them with nuts and bolts. The regenerator acts as a heat exchanger that transfers heat from the hot cylinder to the cold cylinder and vice versa.
  5. Build the displacer: I used a steel pipe as the displacer. I cut it to fit inside the hot and cold cylinders and welded a steel disc to each end. I drilled a hole in the center of each disc for the displacer rod. The displacer moves the working fluid between the hot and cold cylinders.
  6. Build the power piston: I used a steel rod as the power piston. I cut it to fit inside the hot and cold cylinders and attached a piston ring to each end. The piston ring is a rubber seal that prevents the working fluid from leaking out of the cylinders. The power piston converts the pressure of the working fluid into mechanical work.
  7. Build the flywheel: I used an old bicycle wheel as the flywheel. I removed the tire and spokes and welded a steel ring to the rim. I also welded a steel hub to the center of the wheel and attached a bearing to it. The flywheel stores and regulates the rotational energy of the engine.
  8. Assemble the engine: I connected the hot and cold cylinders with four steel rods and nuts. I inserted the power piston rod and the displacer rod through the holes on opposite sides of the cylinders and secured them with nuts. I attached a crankshaft to one end of each rod and connected them with a connecting rod. I mounted the flywheel on one end of the crankshaft and fixed it with a nut. I also attached a valve to one end of the displacer rod and connected it with a spring. The valve controls the timing of the displacer movement.
  9. Test and adjust the engine: I placed the engine on a sturdy table and connected it to a heat source and a heat sink. For the heat source, I used a propane burner. For the heat sink, I used a bucket of water with a copper coil inside. I connected one end of the coil to the cold cylinder and the other end to a faucet. I turned on the heat source and waited for the engine to start. I adjusted the valve and spring until I got a smooth and steady rotation of the flywheel.
  10. Measure the performance of the engine: I used a tachometer to measure the rotational speed of the flywheel. I also used a dynamometer to measure the torque and power output of the engine. I calculated the efficiency of the engine by dividing the power output by the heat input. I found that my engine could reach a speed of about 500 rpm, a torque of about 10 Nm, and a power output of about 5 HP. The efficiency of my engine was about 20%, which is comparable to some commercial Stirling engines.
  11. Improve and optimize the engine: I experimented with different materials and dimensions for the cylinders, regenerator, displacer, piston, flywheel, and valve. I also tried different heat sources and sinks, such as solar panels, wood stoves, radiators, and ice. I found that some changes improved the performance and efficiency of the engine, while others reduced them. I recorded and analyzed my results and made adjustments accordingly.
  12. Use the engine for various applications: I used my engine to power various devices and machines, such as a generator, a pump, a fan, a compressor, and a lathe. I also connected my engine to a battery and an inverter to produce electricity for my home and workshop. I found that my engine was very versatile and reliable and could run on almost any heat source.
  13. Share and teach others about the engine: I was very proud of my achievement and wanted to share it with others. I posted some photos and videos of my engine online and received a lot of positive feedback and comments. I also wrote a blog and a book about my project and explained how to build a Stirling engine from scratch. I received many requests and questions from people who wanted to learn more about Stirling engines and how to make them.
  14. Enjoy the benefits of the engine: I enjoyed using my engine for various purposes and saving money on energy bills. I also enjoyed learning new skills and knowledge and having fun with my project. I felt a sense of satisfaction and accomplishment from building something useful and valuable from scratch. I also felt a sense of responsibility and respect for the environment and the resources I used.
  15. Conclusion

    In this article, I have shown you how I built a 5 HP Stirling engine from scratch using common materials and tools. I have also shared with you the steps, challenges, solutions, and results of my project. I hope you have learned something new and useful from my experience and that you are inspired to try building your own Stirling engine.

    A Stirling engine is a great way to harness the power of heat and convert it into mechanical work. It can run on any heat source, such as solar, biomass, or waste heat. It is also very efficient, quiet, and environmentally friendly. You can use it to power various devices and machines, such as a generator, a pump, a fan, a compressor, or a lathe. You can also use it to produce electricity for your home and workshop.

    Building a Stirling engine from scratch is not only possible but also rewarding and enjoyable. You can design and build your own Stirling engine based on some basic principles and concepts. You can also experiment with different materials and dimensions for the cylinders, regenerator, displacer, piston, flywheel, and valve. You can also try different heat sources and sinks, such as solar panels, wood stoves, radiators, and ice.

    Building a Stirling engine from scratch will also teach you new skills and knowledge and give you a sense of satisfaction and accomplishment. You will also feel a sense of responsibility and respect for the environment and the resources you use. You will also be able to share and teach others about Stirling engines and how to make them.

    If you are interested in building your own Stirling engine from scratch, you can download my plans and instructions from https://www.howibuiltastirlingengine.com. You can also contact me if you have any questions or feedback. I would love to hear from you and see your Stirling engine projects.

    Thank you for reading this article and happy building!


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