3) Building the Cyclone for GEK v3.0

back to Fabrication Instructions for v3.0 kit

Note: You MUST build the Gas Cowling before building the Cyclone to ensure proper fit and assembly of this part!

Parts needed:

     - Cyclone tube 

     - Bottom plate

     - Top flange ring

     - Gas inlet tube

     - Gas inlet square plate

     - 1" close nipple

     - Not pictured: Cyclone Insert tube and plate (see below at bottom)

1. Tack square plate to gas inlet tube

• Fit inlet tube in a vice and clamp to close the open gap and square it up
• Fit square plate over square end of inlet tube, making it flush with edges of tube
• Tack edges of tube and square plate in place, do minimal tacks as some moving of these parts into proper alignment will be necessary later

2.  Fit and Tack inlet assembly over and into inlet passage on Cyclone body tube

• Make sure to fit front "lip" end of gas inlet tube inside of the cyclone tube as seen in the photo. It is the tacked edge to the right in the photo. Also visible from above in the next photo down.
• Again, just 1 or 2 small loose tacks are necessary here as you'll have to move the inlet around later for a proper alignment to the cowling

3. Fit top flange ring over Cyclone tube

• Make sure the vertical seam of the cyclone tube overlaps counterclockwise away from the gas inlet tube, as seen in the above photo and below. Look closely. This ensures a smooth travelling surface for particulate matter to spin around the interior of the cyclone.
• MAKE VERY SURE the top flange ring fits over the top of the cyclone tube exactly as seen in the photo. This puts your bolt holes in the right place, thereby preventing bolting interference by the inlet tube being in the wrong place. It is easy to do this wrong, and other orientations will not work.
• Tack flange ring into place. See 2nd photo below for a suggested clamping. Pull the tube edges tightly to the flange's inner edges. You may have to squeeze and massage the tube a bit to fit the tabs and slots together properly.

5. Flip the tube over and insert the bottom plate, and tack into place

6. Weld 1" close nipple halfway into bottom plate hole

• Make sure nipple is 90 degrees to the plate, fitting half of the nipple's length into the hole
• Tack and then weld it all the way around

7. Tack side seam

8. Fit tacked Cyclone on to Gas Cowling at the gas inlet connection

• Match square plates together and affix with 5/16" bolts and wingnuts
• Using an "eyechrometer" or other helpful device, lift and move the cyclone until it is square to the cowling. The cowling and cyclone top flanges should be in plane, and the cyclone body tube should be perfectly parallel to the cowling body tube.
• Hold in place or clamp as you tack it in the proper alignment 

9. Weld up all seams on the Cyclone

10. Build Cyclone Insert

• Fit Cyclone inner tubing over hole in plate

• Keep 90 degrees to the plate, tack and make a full weld around it.

• Place into top of cyclone, do not weld

back to Fabrication Instructions for v3.0 kit