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A free scan shows the junk files, broken settings and background clutter dragging Windows down - then fixes them in one click.Free scan · Windows 10 & 11A reported modification to a hydronic diesel heater captures exhaust heat to preheat water entering the burner. Hackaday says the builder calculated 95% combustion efficiency, but that figure is not an independently verified measure of heat delivered by the complete system—and the build uses an automotive intercooler that was not designed for exhaust or acidic condensate.
How the exhaust-heat-recovery setup works
In a report published December 13, 2025, Hackaday’s Tyler August described a build by Hangin with the Hursts using an off-the-shelf hydronic diesel heater and a 3-inch automotive intercooler. The heater’s exhaust passes through the intercooler, which transfers some exhaust heat to water entering the burner. Cooling the exhaust this way makes the setup behave like a condensing furnace.
The idea is to reclaim heat that would otherwise leave through the exhaust. But recovering heat is only useful if the heater can still operate safely and reliably, and if the efficiency calculation counts the energy the system actually consumes and delivers.
What the 95% figure does—and does not—measure
Hackaday relayed the builder’s calculated combustion efficiency as 95%; the report says the builder did not trust the result. August clarified: “The efficiency numbers are combustion efficiency, to be clear.”
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The calculation counts energy in the diesel fuel, excludes energy that heats water during the test, and treats blower electricity as free. It therefore is not a whole-system efficiency measurement: it does not account for the useful heat delivered to the water or the electrical input required to run the blower. The accessible report does not provide independent validation or detailed test data sufficient to establish fuel savings.
For context, Hackaday also reported 71% from a previous test of the unmodified heater. The accessible article does not identify who conducted that test or describe its methodology, so the two figures should not be treated as a verified, like-for-like comparison.
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- Phone=Controller: Our latest upgraded diesel heater features enhanced Bluetooth control for even greater convenience. Simply download the app and gain control to preheat your heater from a distance of up to 98 ft/30 m. And it also comes with a 32 ft/10 m remote control and LCD; choose your convenient control method. The temperature can be adjusted from 46 °F-96.8 °F/8 °C-36 °C, catering to your specific needs.
- Automatic Altitude Compensation: Our diesel air heater is equipped with automatic altitude compensation, making it suitable for altitudes up to 18,045 feet/5,500 meters. It adjusts its operation based on the altitude, so you don't have to manually control it. Enjoy seamless heating performance even in high-altitude environments.
- Low Energy Consumption & High Output: Save on fuel costs with our diesel heater's precision low-noise fuel pump, consuming only 1 gallon per night and reducing fuel consumption to a range of 0.16-0.62 L/h. With a 10 L/2.6gal large capacity fuel tank, the diesel air heater can provide continuous heat for up to 16 hours, maximizing fuel efficiency and minimizing energy waste.
- Secure and Reliable: Our diesel air heater features a high safety system, allowing for worry-free usage in various environments such as cars, RVs, and ships. It provides constant temperature control, timing function, voice broadcasting, preheating, and overheating protection at ≥270 °C/518 °F, ensuring a safe and comfortable experience throughout the night.
Why the intercooler raises durability and operating concerns
The reported component is a 3-inch automotive intercooler intended for intake air, not exhaust service. Hackaday notes that it was not made to withstand the slightly acidic condensation produced as exhaust cools. That raises a material and corrosion concern; the report does not establish the intercooler’s suitability for sustained use in this application.
Exhaust restriction is another concern. Hackaday warns that restriction can affect the heater’s air-fuel mix. Adding a heat exchanger to the exhaust path can therefore change more than heat recovery: the heater’s combustion conditions may also be affected. The article does not provide a compatibility list, allowable back-pressure limit, or long-term operating results for other heaters.
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How to interpret the “25% warmer” claim
Hackaday framed the project with the question of whether it could leave someone “25% warmer on the same fuel burn.” That is the article’s framing, not a result supported by detailed measurement data in the accessible report. It should not be read as a demonstrated temperature increase, a guaranteed improvement, or a general fuel-saving claim.
Independent reader supportYour contribution helps us test, update, and keep practical guides available for everyone.What to evaluate before considering a similar build
The report describes one experiment, not a tested comparison of designs. Anyone assessing an exhaust-heat-recovery concept should look at the whole system rather than the combustion-efficiency number alone:
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- Heater type: Confirm whether the unit is hydronic or air-heating; the reported build uses a hydronic heater.
- Heat-exchanger suitability: Verify that materials and construction are intended for exhaust temperatures and acidic condensate. The reported automotive intercooler is not established as suitable.
- Exhaust restriction: Account for how the added exchanger affects exhaust flow and the heater’s air-fuel mix.
- Condensate handling: Consider drainage and corrosion resistance where exhaust is cooled enough to condense.
- Measurement boundary: Include useful heat delivered to water and blower electricity when judging system efficiency, rather than relying on a combustion-efficiency calculation alone.
These are evaluation criteria, not validated design instructions: Hackaday’s report does not establish tested alternatives or provide enough detail to recommend a particular configuration.
What the report establishes
Hackaday’s December 13, 2025 report establishes what the build was intended to do and the limits and concerns it identifies. It does not establish independent performance results, long-term durability, or broad compatibility. The reported heat recovery is an intriguing experiment, but neither the 95% figure nor the “25% warmer” framing is evidence that another heater will achieve the same outcome.
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