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FOG MACHINE CHILLER

The ice-chest is the standard type found in most department stores and only costs around $15.00, but be sure to keep an eye out at garage sales for a used (and cheaper) one. The ABS plastic pipe and connectors are simple to work with, can be found in the plumbing department at all major hardware stores, and the pieces slip together easily.

The first step is to cut a hole through each end of the ice-chest. We used a 4" bi-metal hole saw attached to an electric drill to easily cut perfectly round holes through the center of each end. These unique saw blades (Vermont American Tool Company) can be found at most hardware stores. The bits are a little expensive at around $25.00, so an alternative would be to use a compass to the mark the circle for the hole and then use a jig-saw to cut it out.

Using wire cutters, cut the 1/2" screen wire into a X inch by 12 inch piece. The "X" represents the inside length of the cooler (19-1/2 inches with ours). When cutting the length-wise side cut the further end of the wire so that they are left to stick out. These will be used to attached the wire to its self when rolled (pictured below-left).

Roll the screen wire piece around a spare piece of 3 inch ABS pipe so that it has a basic tube shape. Lower the wire tube into the cooler and slide the 3" id double-female connectors through the holes you cut so that an equal amount sticks out either side. Twist the screen wire into as tight a tube as you can and attach the clamps.

Using needle-nose pliers, bend those end wires you purposely left on under and over the lower screen wire to hold it in its tube shape (pictured center). If a few of these break off its not a problem, but if a lot break off you may need to use some light-weight bailing wire to re-enforce the seam of the wire cage. What you should have is a tube-shaped wire cage that is attached at both ends of the chest (pictured right). This is the chamber that the fog will pass through and be cooled in.

Do not glue these pieces of the intake assembly together. Once they are pushed together they will stay in place. This way if you need to swivel the section or disassemble it you'll be able to.

To help camouflage the unit at night, you will want to paint the exterior of the chest with flat black spray paint. Unfortunately, paint does not stick to the plastic very well, so you will want to prime the ice-chest first. Zinsser B-I-N Primer, available at the hardware store, is a Shellac based Primer-Sealer that works well to prime the plastic ice-chest before painting, and it dries pretty fast. Allow the paint and caulk to dry for 24 hours.

Since we cut the mid-section of 3 inch ABS pipe that runs between the two elbow joints extra long for final adjustment, you will need to set your fog machine on top of the Fog Chiller and cut off any excess ABS pipe until the fog machine's exit nozzle is aligned with the Fog Chillers intake nozzle. Don't cut off to much or you will have to replace the pipe.

Your Fog Chilling unit is now complete and ready to go. When you're ready to use it all you have to do is fill it up to the top with ordinary ice cubes (ours took 35 pounds) and close the lid tightly.

Standard sized ice cubes work great. You should try to avoid very small ice cubes as they might slip through the screen wire into the cooling chamber and impede the flow of the fog. Using dry ice will improve performance, but dry ice costs a lot more.

During use, align the the fog machines exit nozzle to be centered with and about an inch away from the Fog Chillers intake nozzle. This allows outside cool air to be drawn in during operation. The trick to getting the best low lying fog is to use short bursts from your fog machine, separated by a few seconds to allow cold air to refill the cooling chamber.

If you need to direct the exiting fog, you can also attach a section of five inch diameter flexible tubing to the exit pipe on the Fog Chiller to direct the fog where you want it. In general, you don't want to attach more than six or eight feet of tubing, as the fog won't have enough power to travel through its entire length.

The original info can be found at:

http://www.gotfog.com/fog_machine_chiller.html 

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