ASSEMBLY_GUIDE.md

🛠️ ASSEMBLY GUIDE: FIRE-BOX MK II (v2.1)

This guide details the step-by-step construction of the AI-Orchestrated Flash Joule Heating Reactor.

💰 Bill of Materials & Procurement

Component	Specifications	Est. Cost	Sources
Capacitor Bank (x6)	400V 10,000uF (Screw Terminal)	$180 ($30/ea)	AliExpress, eBay
IGBT Module	600V 500A (e.g., PM600DSA060)	$85	IndiaMART, AliExpress
Reaction Chamber	Quartz Tube (12mm ID, 15mm OD)	$25	AdValue Tech, Fisher Sci
Electrodes	High-Purity Graphite Rods (12mm)	$15	Amazon, GraphiteStore
Kill Switch	2-Pole Contactor + Mushroom E-Stop	$80	AutomationDirect, eBay
Logic Controller	ESP32-WROOM-32	$5	Mouser, Amazon
Switching Gear	Gate Driver (e.g., Skyper 32) + PSU	$40	Mouser, DigiKey
Shielding	1/4" Polycarbonate Sheet	$30	Home Depot, McMaster-Carr
Busbars/Wiring	Copper strips + 4AWG Cable	$40	Home Depot
TOTAL ESTIMATE		~$500.00

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🏗️ Step-by-Step Assembly

Step 1: The Energy Reservoir (Capacitor Bank)

Objective: Create a low-ESR energy storage unit capable of rapid discharge.

1. Align the 6 capacitors in two rows of three.
2. Bridge the terminals using Copper Busbars. Ensure massive surface area to minimize resistance.
3. DANGER: Install the 10kOhm bleeder resistors across the output. This ensures the bank self-discharges when powered down.

Step 2: The Echo-Safe Kill Chain

Objective: Install the hardware-level safety interrupts.

1. Mount the Main Contactor to the wall or a heavy base.
2. Wire the Physical E-Stop (Normally Closed) in series with the Echo-Gate Relay (Normally Closed).
3. Connect this series loop to the Contactor's coil. If either "gate" opens, the contactor drops, and HV power is physically severed.

Step 3: The Pulse Brain (IGBT & ESP32)

Objective: Set up the switching logic for the AOMMS waveform.

1. Mount the IGBT Module to a large aluminum heatsink. Use thermal paste.
2. Connect the ESP32 to the Gate Driver.
3. Wire the IGBT Collector/Emitter in series between the Capacitor Bank and the Reaction Chamber.

Step 4: The Quartz Reaction Chamber

Objective: Assemble the "Forge" where the graphene transformation occurs.

1. Cut the Quartz Tube to approx. 150mm length.
2. Insert the Graphite Rods into each end. The rods should fit snugly (seal with high-temp O-rings if using vacuum/argon).
3. Secure the tube in an Acrylic or Aluminum Jig on the reactor base.

Step 5: Final Integration & Shielding

Objective: Final wiring and blast protection.

1. Connect the heavy 4AWG cables from the IGBT to the Graphite Electrodes.
2. Install the Polycarbonate Shield between the reactor chamber and the control electronics.
3. Run the first Dry Test (No sample, low voltage) to verify ESP32 pulse timing via oscilloscope.

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Safety Note: This device creates a massive electromagnetic pulse (EMP) and high-voltage arcs. Keep sensitive electronics (and pacemakers) at a distance.