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How to Make Whistle Fuel
CAUTION!!
Working with pyrotechnic devices is a very rewarding endeavor that can become a lifetime passion. To ensure continued
enjoyment of this hobby, please follow appropriate safety guidelines. Work in an open area outdoors, keep all pyrotechnic
mixtures in closed containers, limit any compositions to only the amount needed for a particular item, store finished items
in an appropriate day box or magazine, be sure to wear appropriate non-synthetic clothing, wear eye protection and keep
a source of water nearby. FireSmith cannot be held responsible for any accidents or incidents resulting from the
construction and use of any pyrotechnic devices. It is highly recommended to check and adhere to all local, state and
federal regulations. Please consider joining the PGI and any pyro clubs in your area so that you may construct
pyrotechnic items in a safe and legal environment. Additional information can be found at www.pgi.org.
Whistle fuel is a very powerful pyrotechnic composition. It is also quite
sensitive to shock and friction. As such, start with small batches and
work outdoors when producing this fuel. A slightly modified version of a
fuel developed by Steve LaDuke, the whistle fuel described in this
tutorial is one of my favorites. It produces a nice “raspy” sound, has good
power, is easy to work with and is very reliable.
Formula:
Potassium Perchlorate 64
Potassium Benzoate 32
Copper Oxychloride 2
Petroleum Jelly 3
Additional Materials:
80-150 Mesh Ti Sponge or Flake 5-10%
20-40 Mesh Screen
Lacquer Thinner
Mason Jar
1 Gallon Ziplock Baggie
Kraft Paper
Latex or Nitrile Gloves
Step 1
It is important that each component be milled to a very fine “talcum pow-
der” consistency. Failure to do so will result in a fuel that will not work.
Should you have chunky chemicals, run them individually through a ball
mill or coffee grinder. Be sure to clean the mill or grinder before
switching chemicals. Absolutely do not ball mill or grind the above
chemicals together. An explosion will result.
Step 2
Weigh out appropriate amounts of each chemical (except the petroleum
jelly) and dump them together into a Ziplock bag
Step 3
Dissolve 5 parts petroleum jelly with lacquer thinner. Approximately 1/3
cup of lacquer thinner for every 500 grams of whistle fuel seems to be
about right. To fully integrate the mixture, set the mason jar with the lac-
quer thinner and petroleum jelly solution in a pot of hot water (do this out-
doors and away from any heat source or open flame). This will fully melt
the petroleum jelly to create a homogenous solution.
Step 4
Dump the petroleum jelly mixture into the bag with the whistle fuel.
Step 5
Knead this mixture for a couple minutes. With the introduction of the
petroleum jelly, the mixture is much less sensitive.
Step 6
Empty the baggie onto your screen.
Step 7
Gently pass this mixture through the screen onto a sheet of paper
Step 8
Repeat the screening procedure 6 times to fully mix the fuel and integrate
the petroleum jelly.
Step 9
Set the whistle fuel out to dry on a sheet of paper or cardboard. Keep it
out of direct sunlight. The fuel is ready to use when it no longer smells
like solvent.
Step 10
Once the fuel is dry, measure out 25% of the fuel and place it into a small
plastic or paper container. Add 5-10% titanium sponge or flake to this
container (80-150 mesh produces a nice white tail).
Step 11
Tumble the mixture for about one minute to fully integrate the titanium with
the whistle fuel.
