March 26, 2019 ... Central U.S. Time

Saturn SL1 Hydrogen Convertor Project Part 2

Posted or updated 11.11.08 by Chuck Russell


Once you have purchased a hydrogen generator, found a location in the car hood area for it, and connected it to the car battery, the job gets easy. The next step is connecting the hoses which will carry the hydrogen, to the fuel system of the vehicle.

This is where my ideas differ a bit from the norm. The installation instructions that came with my hydrogen generator want you to make one connection to the air intake system behind the aircleaner. That works fine for highway driving, but does not address city driving, and sitting at stop lights in idle. The problem as I see it, is that the air intake hose only pulls vacumn while accelerating. There is no air being sucked while idling at a stop light. So I split the hydrogen gas output between the air intake, and the intake manifold. The idea is that the intake manifold pulls vacumn while idling and thus sucks the hydrogen into the fuel system. When accelerating, the intake manifold slowly stops pulling hydrogen and allows the air intake system to literally take over. The idea works well, the car ran much better and smoother, and MPG’s went thru the roof with this type of connection. It also allowed me to run the car with just hydrogen when driving in the flat lands, and staying below 62 mph. I will follow up on that later.

So the delivery system I use for the hydrogen is very simple. First off throw away the nylon hoses that came with the Hydrogen Generator ( if that is what you get). Nylon is thin and it stands up to chemicals and hydrogen gas very well, but it flexes and bends. Any corner or bend you put in a nylon hose is suspect. It also tends to close halfway when you least need that to happen. Nylon hoses want to lie down or sag when the temps get hot as well. You might well find your hydrogen hose on a hot exhaust manifold or spark plug wire. Find a Lowes or Home Depot, then purchase braided heavy duty clear hoses. The material is a mixture of vinyl and polymers. This will cost you roughly 50 cents a ft. Buy $5 worth and you’ll be set. This type of hose is rugged, abrasion proof, has heavy side walls, and won’t close any at all if you turn a corner with it.

Keep your hoses short, see mine is the picture. Take the shortest path you can find. This is better functionally, and it looks better as well. I drilled a hole in the air duct behind my air cleaner and inserted a barbed 3/8” hose connector. This came with my hydrogen generator kit, but it sells for under $3 at any hardware store. I then located my PVC valve and the short hose that connects it to the intake manifold. Yours might be longer. I cut the hose in two, then inserted a white nylon 3/8” tee valve in between the two pieces. See my picture.

This is all the connections you need. I use about 4-5 ft of hose between the two connections. I recommend using black vinyl sealant around the air intake connector to seal any possible leaks. The tee connection will be sealed well from the hose it attaches to on either side at the intake manifold.

Run the hose from the HHO outlet on the water tank to the air cleaner. Cut the hose, put in another nylon tee, and run that to the intake manifold input. That’s it. Simple…

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