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Here’s an idea for modifying a tero cell to seperate Hydrogen and Oxygen.

It’s based on the fully flooded tero cell design I’m currently using for diesel generators, but reduced to 6″ X 6″ for car type amperages. Should run comfortably between 12 and 20 amps.  My diesel units are 12″ X 12″ with 12 cells, designed to run from 60 up to 120 amps @ 24volt. The recirculation reservoirs help keep things cool.

The plates are designed so that they are assembled with the electric tags on opposite sides for each alternate plate. This also alternates the electrolyte feed holes and the output tubes.

I use 5mm neoprene gaskets, but with this modification it would need twice as many gaskets, 2 mm thick, with the seperator material trapped between. Testing thin woven glassfibre cloth for now, but nylon or even ‘J’ cloth may work. Any material that can stand up to the electrolytic action while allowing liquid and electrons to flow, yet fine enough weaqve to keep the hydrogen and oxygen bubbles apart. Make the seperator a fraction smaller than the plate size so that the neoprene gaskets seal the outer edges when compressed.

The outlet tubes are cut from SS brake pipe and should have a bulge flare on the output end for security. Use a small amount of goop to seal them. The neoprene gasket will crush down to make most of the seal. They need to extend inside just beyond the inner gasket edge and the slot in the plates should be kept as small as practical. They will catch gas generated on both sides of the plate.

Use an EVEN number of plates so that each plate takes on the opposite polarity to the next if running as a series array. Positive to one end plate and negative to the other, with the rest getting their polarity via the electrolyte. Use 6 plates for 5 cells, or 8 plates for 7cells, but note that 7 cells is pushing the electrolyte strength into orbit. 11 plates can be wired -ve at each end and+ve to the centre for 2 x 5 cell series units in parallel.

Or play with different combinations using the tabs on each plate. That is the best feature of this design, easy to try combinations, and also easy to dismantle/rebuild to make changes. No glue except the goop holding the output tubes to the plates/gaskets.

Use 2 seperate reservoirs to collect the gasses, one fed from the tubes over the negative plates for hydrogen, the other from the tubes over the positive plates for oxygen. Returns from both reservoirs feed back into the cell via fittings in the end plates.

If the amount of S/S drilling is a problem, make oversized end plates like the original Tero and arrange the bolts around the outside of the s/steel plates. Use thicker end plates made from acrylic to minimise distortion. That reduces the hole drilling to 1 per plate. Use 22 or 24 gauge 304 or 316L and the slots and electric tags can be cut with hand snips. With thin guage S/S yellow crimpon cable connectors can be used, cut the tags to fit. 10g wire will handle the 20amp current. Or leave the tag larger if you prefer to drill for a bolt on connection.

Have fun.