Gen 15 Hydrogen fuel system in Dewalt Toughbox 2

Update March 9 2025

Gen 15 Hydrogen fuel system mounted into a Dewalt Toughbox2

The latest model off the Gen 15 Hydrogen system is now mounted securely into a Dewalt toughbox2 measuring 53 cm x 34 cm x 35 cm high. Originally we have mounted these systems directly into the Dewalt Box walls , where they operated excellently generating 3.6 Litres of HHO gas per minute at 12.6 volt and 29 amp.

So as to make the system more suitable for trucking applications and heavy duty 4 wheel drive applications we have improved the system by mounting all parts onto a steel frame.
The steel frame is made of 2 mm thick mild steel .

The assembled system on the steel frame is then lowered into and firmly secured to the base of the Dewalt Box. Ths type of assembly offers the toughness and resistance of a HDPE plastic Dewalt tool box as well as the rigid security of the 2 mm thick steel frame.

The Steel frame allows all components to be securely mounted onto a rigid frame . Mounting the steel frame assembly into the Dewalt Toolbox , allows all parts of the system to me easily serviced.

The Plastic HDPE frame of the toolbox absorbs and vibrations form the vehicle as well as providing a tough box that can absorb impact loads without damaging the internal hydrogen fuel system cells , pump or electronics.

Dewalt Tough-box 2 assembly is a thick HDPE plastic enclosure which can be easily sealed and locked with three locking points . It is suitable for this system as it has sufficient air space within to prevent overheating and is therefore perfectly suited to the Arid Australian outback conditions for Trucking , Mining and Farming .

This system is ideal for work vehicles, Generators, Trucks and Mining and Farming equipment with engine capacity to 10 litres. For larger engines two or more of these units can be connected together to provide the required gas output. This model system was recently used in Road tests on a 2022, 27 tonne , 7.2 litre Diesel truck and produced savings on 31% and 32%. (see webpage report)

Photos below show the 2 mm thick steel frame onto which the Hydrogen Generator system components are mounted. This steel frame is then lowered into the Dewalt Tough-box whch is coated with a thick layer of Sikaflex . This Bonds the assembly to the box base.

The Adhesive Sikaflex was used as a bonding agent because of its shock absorbing / flexible / compressible nature and high binding strength .

Latest developments for these systems include the use of new Resin filter system to increase the purity of the water electrolyte . This development removes impurities from the water to produce Chemistry laboratory grade distilled to produce a purity of 52ppm from tap-water (800pm) or ground water 1500 ppm.

Removing impurities prevents any unwanted oxidation of the anode of an electrolysis unit , producing more gas for the electrical energy input and wasting much less energy as heat.

The Resin filter capsule is able to produce 50,000 litres of pure water and has a lifespan of 5000 hours. The Capsule is easily replaced / serviced with a new filter module. Contact Gavan on 0403177183 for more information of this produce. Photos of the resin filter is seen on the “Shop” on this site.

For more detailed information or any specific queries, please feel free to contact our technical support team.

For More information on this system call Gavan +61 0403177183

0403177183 or email glknox11@live.com