I'm using the plasti-dip method, in addition to other changes. One extra neutral ( now 5n ), 3 cups KOH per gallon of water and P-channel mosfets I've reralized 34% increase over last year. Of course my electrolyser wasn't producing what it was rated at and now it's doing a little more. I'm happy with it. The plasti-dip is easy to do.
Alpha-dog, I am glad to hear that the Plasti Dip is working for you but what is the difference between p channel fets and n channel fets. I am curious as to why that would help I do not have even 1 tenth of the understanding of electronics as you do. Maybe it is something I want to try as well.
Larry
What I know is that I've tried with my test electrolyser both N-channel and P-channel with the same current draw and the P-channel fets on the pwm gave an increase output. My theory is that with the N-channel fets you have a saturated electrolyser all the time and by turning on and off the ground you allow it to conduct for a period of time. With the P-channel fets the electrolyser is conducting all the time both with stored energy and comming from the battery in pulses. So with N-channel fets you have an off time and with P-channel it always conducts. I have proven on my test set and on my vehicle that it work better.
Tundra here's a MMW calculator:
http://site.altpropulsion.com/MMWCalc.htm
If you will be patient, I and an engineer friend are going to produce a beta run of a new pwm design. I want to make it modular, versatile and reliable with current control, choice of N-channel or P-channel mosfets, able to operate at up to 25khz. Safety is always the first issue, so it needs to use the minimum amount of heavy current bearing wires. You should also be able to buy extra fet blocks for higher current usage, which will make upgrades cheaper.
Russ