Here are the promised pictures of my adventure today. And a link to a video of the hydrogen being produced. So without further adieu...
This is the aftermath of my test today and the result of lighting the output tube to see how much HHO was being produced. The answer? Enough to snap the lid into two parts - knocking the core of it completely out and then snapping the collar of the lid and ejecting it off the bottle about a foot.
This is a close-up shot of the edge of the center of the lid. This is was the primary point of structural failure.
Zoomed out shot, showing how I had it sitting in my car and a shot of the Mt. Dew bottle I couldnt get to bark any burn out of, so I ended up lighting the exhaust tube instead to test it - thus ending with the lid 'splosion.
So what have we learned? The first cap design was a little too complex. I've slimmed down the version 2 design and made the second version in about 15 minutes. You can make fine tip nozzles for Goop glue tubes with electrical tape in a pinch. Super Glue is overrated and doesnt bond most things together for very long so totally skip that part. The jar has a very small likely hood of bursting since it's thick and full of water. If the system is breached by combustion, the lid will always be the weak spot. An internal kill switch is definately needed when installed.
Tomorrow or the day after I should have the Version 2 installed in my car and we'll see what that does. Wish me luck.