| Step 2: Preparing the materials for assembly To make sure everything goes together properly and smoothly, proper conditioning and sizing of the materials is necessary. Pay particular attention to the shaping of the pipe ends, as this is a major factor in proper solvent welding with the fittings. PVC PIPE SIZING Cut the two pipes to size, 10" and 36" with the saw unless you already did so in the store. Using the file, take off the sharp corners on the inside AND outside of the pipe. Radiusing the inside helps reduce the amount of potato scud that can build up in the launcher, and breaking the outside corner ensures proper solvent welding, if this is not done leak paths may result. Cut ends should be as square as possible. To one end of the 1 1/2" pipe it is suggested that the inside be chamfered about 0.020" and the outside filed or turned down to almost meet the inner chamfer, creating a blunt knife to help size the potato. It will work without out this step, but a lot messier! PVC FITTINGS Inspect the fitting for really bad weld lines or possible large dislocations that may result in premature failure. Remove all paper tags or labels by peeling, scraping, even using a bit of primer to clean off the last adhesive. File off any sharp sprues that may hamper your ability to grip the fittings firmly when assembling. IGNITION SYSTEM Cut the wire into two equal lengths. Strip and twist each end about 3/4" back. Taking the BBQ igniter, upon inspection you should find a plug on the tail end (one electrode site) and close inspection should reveal a very fine wire embedded in the side body of the igniter, close to the button lip. This fine wire is attached to the igniter nearest the button, as the wire is just pressed into this slot which might be about 3/4" long. Carefully extract the other end of the wire with the knife, removing all but the last 1/4" or so from the slot. Carefully twist this wire to one end of one electrode wire stripped previously. Immediately solder this connection together taking care to not break or extricate the fine wire from the plunger body. Cool with spit (really!), dry, and tape this joint back against the body with electrical tape, using enough to immobilize the wire with gentle tension. Take the wire supplied with the igniter, the one with the plug that fits on the base, and cut leaving about 2" from the plug end that will fit into the base of the igniter. Strip and twist this stub to the other electrode wire, soldering, and taping over the solder joint. You now have an igniter to make a 'remote' spark. Try it holding the two free electrode wire ends about 1/4" apart--don't touch them! (your BBQ igniter may be a bit different, the idea is to get both electrodes away from the igniter, so you don't make a big hole in the launcher combustion chamber.) |