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I remember a long time ago reading about a VW that was converted to steam power using freon (long before R12 was found to be bad for the ozone layer).
Your main issues.
Insulation to maximize heat retention.
What fluid to use that would provide enough lubrication to ensure longevity.
To be "self starting" you must have 3 cylinders or some means of initiating rotation of the engine.
Using a flywheel to store energy and pulsing the flywheel, then engaging the field on the alternator will probably be necessary, kind of like a pulse and glide strategy that would give you usable power.
An enlarged pipe section immediately behind the catalyst, with a spiral wound stainless steel tubing coil, will be the best source of heat (my opinion).
I once measured the temp of the header on an idling Nissan Z engine and the thermometer only read 175 degrees, so you might consider a fluid with a lower boiling point than water.
Not trying to be negative about your quest.
I think DYI may not be practical, but the wasted energy (67% on average according to DOE figures), certainly is an enticement to trying to find a solution, and it will require great perseverance (like getting a Patent) to succeed.
I still think my previously linked functional prototype is probably the best solution to actually get something working, but building a from scratch working system would be very cost prohibitive.
The Stanley Steamers used a tube boiler because it made boiler explosions a non event.
regards
Mech
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