Tiffany Haney
Building a flue pan is no easy task, requiring a lot of practice and preparation. It is a time-consuming process that involves bending, welding, and soldering. A flue pan is used to increase the evaporation rate by creating more surface area. The smoke and other gases created by the fire travel through the flues of the pan, allowing for the capture of as much heat as possible from the wood. The size of the flue pan will determine the number of flues and their height. The purpose of the flues is to eliminate the build-up of sediments on the floor of the pan by allowing the flow of sap to be reversed.
| Characteristics | Values |
|---|---|
| Purpose | To increase the evaporation rate by creating more surface area |
| Flue size | 5" or 7", with deeper flues leading to a greater gallons-per-hour rate |
| Tools | Bending brake, vise grips, clamps, welding equipment |
| Time | 2-3 hours for bending, 2-3 hours for welding, 10-15 hours total |
| Cost | $250 CDN for a sheet of 20-gauge mill finish stainless steel |
| Advantages | Double the surface area, more efficient boiling, higher evaporation rate, less wood used, better syrup quality |
| Disadvantages | Time-consuming, difficult to clean |
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What You'll Learn
Welding and soldering
On the other hand, soldering is a process in which two pieces of metal are joined without melting them. Instead, a dissimilar metal is used to fill the gaps. The solder dissolves and alloys with the metals being joined in a process called "wetting". Solder is not meant to provide high-strength connections, but rather to create a continuous connection.
When deciding whether to weld or solder a flue pan, there are several factors to consider. Firstly, welded pans are simpler to make and are more durable than soldered pans. If a soldered pan flexes too much, it will come apart unless the joints are locked together before soldering. Secondly, the design of the joints differs between welding and soldering. When welding a corner, the two edges are butted together and then fused. In contrast, soldering requires an overlapping joint, with solder used to seal between the overlapping pieces.
There are various techniques and tips for soldering flue tubes, which are components of flue pans. One technique involves coiling solder around a rod so that when relaxed, the coil can slip over the tube. The coil is then cut into closed-end rings, and a ring is placed over the end of each tube and covered with flux. Heat is then applied to the joint, causing the solder to flow into it. It is important to avoid putting the torch directly on the joint until the flux has melted into a clear liquid. Another technique for soldering copper tubes in a steel boiler involves extending the tubes past each plate and making axial notches around the bore. The boiler is then stood on each end so that the solder flows around the tubes and through the bore.
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Flue size and number
The size and number of flues in your flue pan are important factors to consider when building one from scratch. The flues play a crucial role in increasing the evaporation rate by providing more surface area for boiling. Deeper flues will generally result in a higher gallons-per-hour (gph) rate.
Most flue pans have flues that are either 5 or 6 inches in diameter, although some newer models have larger flues. The number of flues you include will depend on the size of your pan and the desired evaporation rate. You will need to determine the height of your flues and the amount of material required accordingly.
When building a flue pan, it is essential to consider the complexity of the welding process, especially when dealing with light-gauge metal. Back gassing with argon is necessary to avoid sugaring, which can be challenging to tape off from the underside of the flues. Additionally, the bending and welding of the flue ends to the pan require precision and practice.
It is worth noting that the design of the flue pan can impact the efficiency of boiling. By “folding” the bottom of the pan, you can increase the surface area, enhancing the boiling efficiency. Regular maintenance, such as “punching” the flues to remove soot, is also necessary to ensure optimal performance.
Overall, constructing a flue pan with the desired flue size and number requires careful planning, welding skills, and an understanding of the underlying principles of evaporation and heat capture.
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Reversing the flow
There are two ways to reverse the flow. The first is to turn the pan 180 degrees. The second is to use a Same Side Reverse System, which allows you to change the direction of the flow without moving the pan or dealing with plugs. This is done by swinging the handles of two specialised Ball Valves.
The flow of sap is controlled by the drain port on the Inlet Float Box, which can be outfitted with a Valve or a Deluxe Sight Glass. The sap depth in the Flue Pan is also controlled by the Transfer Float Box, which can also be outfitted with a Valve or Deluxe Sight Glass.
The purpose of the flues in the pan is to increase the evaporation rate by creating more surface area. This is because liquid mostly boils on the surface of the pan. By "folding" the bottom of the pan, you can increase the surface area and make boiling more efficient. The smoke and other gases created by the fire travel through the flues of the pan, capturing as much heat as possible from the wood.
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Bending the sheet
Firstly, determine the number of flues, their height, and the overall design of your flue pan. This will help you calculate the amount of material needed. Stainless steel is a popular choice for flue pans due to its durability and heat resistance. Consider using a sheet of stainless steel with a thickness between 3mm to 6mm to ensure heat retention and structural integrity.
The next step is to mark the cutting lines on the sheet metal. Use a grinder or a jigsaw to cut the metal sheets according to your measurements. Be cautious and precise during this step to ensure straight and accurate cuts. Once the sheets are cut to size, you can begin the bending process.
When bending the sheet, take your time and work methodically. Make sure the hold-down bars are appropriately positioned to prevent overbending or underbending. Depending on the complexity of your design, you may need to flip the sheet multiple times to create the desired shape. Always wear appropriate safety gear, including gloves and eye protection, when working with metal sheets and bending tools.
Finally, once you've achieved the desired bends, you can use techniques such as welding, soldering, or riveting to join the pieces together and give your flue pan its final form. Take your time during this assembly process to ensure a sturdy and leak-proof construction.
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Tools and materials
Building a flue pan requires a variety of tools and materials, depending on the specific design and requirements. Here is a detailed list of the tools and materials you will need to build a flue pan:
Tools:
- Bending brake: This tool is used to bend and shape the metal sheets for the flue pan. While it is possible to fabricate a flue pan without a bending brake, having access to one will make the process much easier and more precise.
- Welding equipment: A good welding setup is essential for joining the metal pieces together. MIG welding is commonly used for fabricating flue pans, but TIG welding is also an option.
- Clamps and Vise Grips: Clamps and Vise Grips are necessary for holding the metal pieces in place during the welding process and ensuring precise alignment.
- Tweaking tool: A simple tweaking tool can be fabricated from bar stock and square tubing, along with nuts, bolts, and a C-clamp. This tool helps to tighten up the bends and square the joints.
- Cutting tools: You will need appropriate cutting tools to cut the metal sheets to the required size and shape. This may include metal shears or a plasma cutter.
- Measuring tools: Accurate measurements are crucial, so a tape measure, ruler, or similar tools are necessary.
- Crimping tool: If you plan to install a rain cap on your flue, you may need a crimping tool to adjust the size of the cap's stub section.
- Drill: A drill is needed for installing a rain cap, along with self-drilling screws.
Materials:
- Metal sheets: The type of metal used can vary, but stainless steel is a common choice for its durability and corrosion resistance. The size and thickness of the sheets will depend on the design of your flue pan.
- Chimney pipe: The dimensions of the chimney pipe will determine the size and shape of your flue pan. Ensure you follow local and national fire codes when selecting the appropriate dimensions.
- Rain cap: A rain cap is essential to prevent water, debris, and animals from entering the flue. They are typically made from stainless steel, galvanized steel, or copper, with a mesh or wire enclosure.
- Chimney cap: The chimney cap covers the top of the brick flue housing and is usually made from stone or concrete. It helps to keep out moisture, animals, and debris.
- Fasteners: You will need appropriate fasteners such as screws, nuts, and bolts to secure the various components of the flue pan together.
It is important to note that the specific tools and materials required may vary depending on the design of your flue pan and any local regulations or codes that need to be followed. Always consult relevant guidelines and seek professional advice if necessary.
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Frequently asked questions
A flue pan is used to increase the evaporation rate by creating more surface area.
First, you need to bend the sheet of metal. Then, weld the ends of the flues to the pan. Finally, bend up the sides of the pan and add the ends.
You will need a sheet of metal, clamps, vise grips, and a welding machine.
The flues in a flue pan increase the surface area, which increases the evaporation rate. The smoke and other gases created by the fire travel through the flues, capturing heat from the wood.
Building a flue pan can be a rewarding project that allows you to customize your setup. It can also be a cost-effective alternative to purchasing a pre-made flue pan.
