Kudos for playing with this.
An idea for when you get her back together, setup a water injection pulse width controller to keep the exhaust temps at a certain temp? Like, it could vary how much water to inject to keep the exhaust at say, 700 degrees or lower. This would conserve water, and help prevent thermal runaway.
It wouldn't prevent the failure you observed, but it would be an improvement i think.
Regarding the NOx production. I would suspect that it's not as bad as you think. The water your injecting should keep the peak cylinder temps down.
Really cool project.
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