Assembling the boiler:
Use a box cutter or work shears to cut the top and bottom off of the soda can. Keep the bottom (a concave circle), and cut down the length of the side to get a flat sheet. Be careful! And consider wearing work gloves when handling the cut aluminum;
the can edges will be very sharp.
Trim the bottom of the can so it is just the inner concave part leave about an 1/8" extra "lip". Cut perpendicular slits all the way around the 1/8" lip.
Trace the can bottom onto the flat part of the can and cut out the circle.
Sand both sides of the flat circle then bend the circle several times so it is no longer flat. This is what will allow it to "pop" when it is heated.
Take two lengths of 6 inch tubing and bend them into a L shape. (We used some left over 1/4" soft copper, but any metal tubing will work)
Mark the concave part of the can and drill two holes into the can for the tubing
Insert the tubing into the holes and epoxy them in place. To make sure the tubing is flush with the inside of the can, support it with a block of wood covered with plastic wrap or wax paper while the epoxy cures.
Once the epoxy cures, take the circle you cut from the flat sheet and epoxy it into the top of the can bottom (now your boiler!), and bend the tabs you created by cutting the slits over. Crimp them in place using pliers.
While the epoxy cures, build your hull. We used another soda can for this, but you could also use a milk carton, plastic soda bottle, styrofoam block, sardine tin, or anything you can come up with that will hold your candle and give you a transom to support your exhaust/intake tubes with... get creative!
Drill two holes in the transom of your boat for the tubing to fit through. Insert your steam engine into the hull.
Make sure that your boiler tilts up slightly when it is in place!This small adjustment will have a significant impact on your boiler's effectiveness.
Fill up the tub or a large basin outside and prime the exhaust pipes with a little water. Place the candle under the boiler and light it, and fingers crossed, wait for your boat to start putt putting along!
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