To support development and hardware‐based testing of various space reactor concepts, the Early Flight Fission‐Test Facility (EFF‐TF) team established a specialized glove box unit with ancillary systems to handle/process alkali metals. Recently, these systems have been commissioned with sodium supporting the fill of stainless steel heat pipe modules for use with a 100 kW thermal heat pipe reactor design. As part of this effort, procedures were developed and refined to govern each segment of the process covering: fill, leak check, vacuum processing, weld closeout, and final “wet in”. A series of 316 stainless steel modules, used as precursors to the actual 321 stainless steel modules, were filled with 35 +/−1 grams of sodium using a known volume canister to control the dispensed mass. Each module was leak checked to <10−10std cc/sec helium and vacuum conditioned at 250 °C to assist in the removal of trapped gases. A welding procedure was developed to close out the fill stem preventing external gases from entering the evacuated module. Finally the completed modules were vacuum fired at 750 °C allowing the sodium to fully wet the internal surface and wick structure of the heat pipe module. © 2004 American Institute of Physics