Make A Homemade Ultralight Camping Stove

Hello everyone, my name is Bennett and I am a weight weenie. There, I admitted it. This post will show you how to make an excellent minimalist stove for multi-day backpacking and self- supported bicycle touring. You will be amazed at how much you obsess about weight when you have carry everything you need on your back or in bicycle bags. Wilderness camping and exploring affords the adventurist few comforts. A hot meal is a massive boost to morale and improves the experience. This is especially true for someone on their first adventure. If you do this right,  you will have a hiking partner for life. If you screw this up then you will be hiking alone or worse, you might be spending your weekends at the shopping mall. Great outdoor wilderness experiences are made from a 3 basic fundamentals. You will need:  
  1. Shelter (A good tent, sleeping pad and bag.)
  2. Good Clothing/Gear (Proper Boots, Backpack)
  3. Hot Meals (A reliable lightweight stove.)
We will cover numbers 1 and 2 in another post. This discussion is about how to create hot meals with a reliable stove that does not weigh as much as a brick or cost as much as a five course meal. This stove was cheap, easy to make and serves its purpose very well. The goal with this stove is to boil water. We are not cooking a pot full of seafood gumbo or your favorite chili recipe. The point here is to make something hot, edible, fast! Here is what you will need:
  • Cheap $1 extruded aluminum bottle from the Dollar Tree or similar bargain store. DO NOT go out and buy a $20 SIGG bottle. The cheap versions are less rigid and work best.
  • A cutting tool. It is not necessary to use a dremel tool with cutting wheel. It just made the job easier. You can use an affordable hand saw as well.
  • Drill and drill bit in the size of 1/32. You can also use 1/16 bit and make less holes.
  • Sandpaper in 60 grit.
  • Measuring tool like a small tape measure or a ruler.
  • Sharpie or permanent marker.
Additional items: This stove burns denatured alcohol (preferred). It will also burn isopropyl alcohol (rubbing alcohol 70%). 2oz lasts about four minutes in the stove. You can get denatured alcohol at almost any hardware store. Make a wind screen and ground mat out of tin foil. This serves as a wind break which greatly improves efficiency. The ground mat helps prevent your stove from catching the forest on fire. Make the tin foil windscreen and ground mat by sneaking into your kitchen while your wife is asleep and snag all of her tin foil. Make two pieces 12″x12″ each. Fold them in half for strength. Step 1: Measure
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Cut Carefully
Make a mark on your bottle approximately two inches from the top, not including the plastic cap. This mark should be 1/2 of an inch below the spot where the bottle starts to expand.   Step 2: Cut
prepper stove, ultralight camping stove
Step 2 Cut the Base
Carefully cut the circumference of the bottle separating the two inch section from the rest. Do your best to maintain the 2″ measurement all the way around, evenly. Use the freshly cut two inch bottle piece, place it next to the base of the bottle. Mark the base of the bottle two inches from the bottom to mach the piece that was previously cut. Your goal here is to create two pieces that mach when pressed together. The bottom cut should be two inches in height just like the top piece.   Step 3: Invert and Press
prepper stove, ultralight camping stove, homemade backpacking stove
Step 3 Invert and Press
Place the two inch high base facing up. Invert the two inch piece, with the bottle spout, facing down. Press the two pieces together. Note: DO NOT press the top of the bottle all the way into the bottom. There should be a small gap inside the pressed pieces so the fluid can seep into the chamber. This gap should be 1/32 in width. Step 4: Sand
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Sand to Even Out
Invert the newly pressed pieces together. Lightly sand the open end of your new stove on a flat hard surface. This should even out the ends of the two pieces that have been pressed together. Step 5: Drill
prepper stove, ultralight backpacking stove
Drill Evenly
Measure one drill hole approximately 1/2 inch from the top or just slightly below where the expansion chamber starts from the top. If you are using a 1/32 bit then you will have twice as many holes as you have if you are using 1/16 bit. Be sure they are evenly spaced all the way around. These holes are where the heated alcohol that transforms from liquid to gas escapes creating flames. Step 5: Fill and Light
ultralight homemade stove, prepper stove, backpacking stove
Drain Alcohol to Chamber
Fill your new stove with approximately 2oz of denatured alcohol. DO NOT OVERFILL. Swirl the liquid around in the bottom for it to seep into the chamber. Light the small amount of alcohol that is left in the bottom of the stove. The flame will be faint and difficult to see. In approximately 30 seconds to 1 minute, you should hear and see the alcohol start to slightly boil and turn to a gas. Small flames should begin to emerge from the drilled holes in the side of the stove. Step 6: Cook! After the flames start to aggressively exit the drilled holes, you can place your pot on the stove. Expect boiling water in less than 3 minutes.
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Cookin Wit GaZ
Stove Comparison: Below is an image of 3 of the most popular ultralight backpacking stoves. List from the left to right are MSR Whisperlite, MSR Pocket Rocket, Optimus Nova, Jetboil Flash and my homemade stove I call the Little Green Flame Monster. IMG_1518
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