Gear: Build your own Utra-light Backpacking stove

Some call this a Pocket Stove, Soda Can Stove, or a Beer Can Stove

With some basic hand tools and free material you can build a highly functional, ultra-light backpacking stove.  These stoves burn readily available Denatured Alcohol.  The best part, as you backpack and use fuel, your pack weight will continue to decrease with each use.

While we have never had a safety issue with these personally, you do agree that we are in no way responsible if you decide to build one of these.  You assume full responsibility for yourself and those around you.  Denatured Alcohol burns nearly invisible.   In bright sunlight it is nearly impossible to see the flames.  There is a high risk of being severely burned if you do not pay attention and handle the fuel with respect and caution.  Also make sure your stove is on a stable non flammable surface.  Never use indoors or in a tent.  It is easy to tip one over with liquid burning fuel running everywhere. 

The basic principle of it's operation is the fact a double walled chamber is created.  Once the fuel begins to burn and the pot is placed on top, the liquid alcohol is heated and vaporizes in the chamber between the walls.  The heated and expanding vapors are forced out through the small pin holes and burn hot while under pressure.

1 oz of Denatured Alcohol in most cases burns long enough to boil enough water to reconstitute a two person Dehydrated type backpacker meal.

The basic construction is shown.  More detailed construction can be found searching the internet and places like youtube.  There are also a large variety of different methods and the final product designs.

Once constructed, pour your 1 oz of Denatured Alcohol inside, as well as dribbling a small amount over the outside metal.  Some people suggest using a "primer" dish such as a metal lid.  Either way, the idea is to get all the stove metal heated to start the vaporization going.  After priming about 15 to 30 seconds, slowly place your pot directly on the stove.  If everything is heated and burning, and you lower the pot slow enough onto the flames, you basically seal off the inner pan with all the liquid alcohol, the heated metal will vaporize the liquid forcing the vapors out the pin holes.  Flames will start around all the little side burner holes and your stove will operate until the alcohol is consumed.

Carry several layers of aluminum foil when backpacking to unfold and create a "Wind Shield" when needed.  That is the only drawback of using these stoves.  Wind makes for a difficult start up.

First read through all the steps to understand the construction before making any marks or cuts.

Tools that are helpful.
Ruler
Sharpie Marker
Scissors
Small flat jewelers screw driver
Hole Punch
Stick Pin
Needle nose pliers
Exacto Knife
Can Opener

Mark can to make the two cuts shown

Remove the top using a can opener, and discard

Mark about 16 places around the top as shown
and punch through the aluminum using the stick pin

Make your two cuts with the exacto knife

Create this ring by cutting a slit half way on each
end to interlock with one another.  This ring has
to fit down into the bottom part and up into the
upper part.  See figures below and fit before
making your slits.  Once satisfied, mark, then slit,

Using hole punch make 3 half holes at the edge that will
become the bottom of the inner chamber ring.

Flip the top piece upside down.  Using your flat
jewelers screwdriver, carefully open up the crimped
edge all around the opening.  The inner chamber ring must be able to slide inside this opened crimp.  The
diameter of your inner chamber ring should be
made to this size.

Hold the bottom piece and using your needle nose
pliers crimp and twist slightly all around the cut edge.  This takes up some of the metal so that the bottom piece can slid into the top piece.  Mark a
line around the bottom piece 1/2 inch from the cut
edge.

Place the actual top piece with the top down on a flat surface such as a table.  The inner chamber ring goes into the opened crimp of the top with the hole punched edge facing up toward the bottom that you will be putting on.  The trick here is to eyeball that ring and adjust its top to bottom length by trimming with your scissors.  Trim slowly so you don't trim too much.  Dry fit a couple times but not all the way.  The ring must fit into the crimp of the top as well as bottoming into the ring depression of the bottom piece...after the bottom piece is inserted and slipped up into the top piece to the marked line. 

 Once you have fit the parts together the sides should be tight.  It may take some work to fit them together.  Work it on with steady pressure all around. If you get going at a slant the top or outer piece will more than likely rip.  Wear gloves and take your time.  Once that fit is made, crimp that edge at the top opening using your pliers to secure that inner chamber wall to the top piece.



You are ready for a test burn.  Pour in 1 oz of alcohol and run a small amount over the outside.  Then light.  Remember to get the stove fired up before attempting to place your pot on top.  After ignition wait 15-30 seconds for everything to heat up.  Next slowly lower your pot and place directly on top of the can stove.  Watch as you do this.  If all is right you should see the pressurized flames ignite just as you set the pot down.  It may take a couple of attempts to get the hang of it.  Once it gets going it looks like any other gas burner and produces a surprising amount of heat.