t-Butyl diazoacetate (CAS NO.: ), which is known as , diazo-, tert-butyl ester, could be produced through the following synthetic routes.

A. p-sulfonyl azide (CAS NO.: ). A solution of 71.5 g. (1.10 moles) of sodium azide  in 200 ml. of water is placed in a 2-l. Erlenmeyer flask and diluted with 400 ml. of 90% aqueous ethanol. To this solution is added with stirring a warm (45°) solution of 190.5 g. (1.00 mole) of p-toluenesulfonyl chloride in 1 l. of 99% ethanol. During this addition, sodium chloride separates, and the reaction mixture has been stirred at room temperature for 2.5 hours, most of the solvent is removed at 35° (15 mm.) with a rotary evaporator. The residue is mixed with 1.2 l. of water in a separatory funnel, and the oily p-toluenesulfonyl azide is separated. This oil is washed with two 100-ml. portions of water and dried over anhydrous sodium sulfate. Filtration with suction gives 160–170 g. (81–86%, based on p-toluenesulfonyl chloride) of pure, colorless p-toluenesulfonyl azide which completely crystallizes on standing at 5°.

B. t-Butyl α-diazoacetoacetate (CAS NO.: ). In a 2-l., wide-mouthed, Erlenmeyer flask are placed 118.5 g. (0.75 mole) of t-butyl acetoacetate, 1 l. of anhydrous acetonitrile, and 75.8 g. (0.75 mole) of previously distilled triethylamine (b.p. 88.5–90.5°). The temperature of the mixture is adjusted to 20°, and 148 g. (0.75 mole) of p-toluenesulfonyl azide is added dropwise with vigorous stirring over 10–15 minutes. The addition causes the reaction mixture to warm to 38–40° and assume a yellow color. After the mixture has been stirred at room temperature for 2.5 hours, the solvent is evaporated at 35° (12 mm.). The partially crystalline residue is triturated with 1 l. of ether, and the mixture, including the insoluble residue, is placed in a 2-l. separatory funnel. The mixture is washed successively with a solution of 45 g. of potassium hydroxide in 500 ml. of water, a solution of 7.5 g. of potassium hydroxide in 250 ml. of water, and 250 ml. of water. The yellow-orange ethereal phase is dried over anhydrous sodium sulfate, and the solvent is evaporated at 35° (15 mm.) until the residue has attained a constant weight. The yellow-orange diazo ester weighs 130–135 g. (94–98%).

C. t-Butyl diazoacetate (CAS NO.: ). Into a 1-l. three-necked flask fitted with a stirrer, a dropping funnel, and a thermometer is placed a solution of 92.6 (0.50 mole) of t-butyl α-diazoacetoacetate in 150 ml. of methanol. After this solution has been cooled to 2–3° in an ice bath, a solution of sodium methoxide, prepared from 11.5 g. (0.50 g. atom) of sodium and 150 ml. of methanol, is added dropwise with stirring at such a rate that the reaction mixture remains within the temperature range 0–5° (about 30 minutes is required for the addition). After the addition is completed, the mixture is stirred in the ice bath for an additional 30 minutes. The red reaction solution is poured into 1 l. of ice water, and the resulting mixture is extracted with 500 ml. of ether. The aqueous phase is saturated with sodium chloride and extracted with two 500-ml. portions of ether. The combined ethereal extracts are washed with 500 ml. of water and dried over anhydrous sodium sulfate. After the mixture has been filtered and the residue has been washed with ether, the bulk of the solvent is removed from the combined ethereal filtrates at 30° and water aspirator pressure with a rotary evaporator. The remaining ether is removed by distillation under slightly reduced pressure while the stillpot is heated with a water bath at 50°. The residual red oil is distilled. (Caution! See above.). After a small forerun the diazo ester distills during which time the temperature of the water bath is raised from 60° to 75°. The yield is 48–50 g. (68–70%) of yellow-orange liquid, b.p. 51–53° (12 mm.), n²⁰D 1.4551, R_f = 0.56 (chloroform).

Notice: s are toxic and potentially explosive and must be handled with caution. This preparation should be carried out in a hood, and the distillation of t-butyl diazoacetate should be conducted behind a safety shield.