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Old 09-27-2010, 10:21 PM   #181
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Location: OROVILLE, NORTH CENTRAL, WASHINTON
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Re: CHANGED AGAIN! THIS WILL BE IT!!

[quote="BUSBOZO"]Well, I finally found a RV generator about 45 minutes from me. The guy had it listed on Craigslist for $500 with all the manuals! I've been looking everyday for weeks. Boy, these are hard to find in the local area!

Its a ONAN 6500 Watt twin cylinder gasoline Genset. Its the old dinosaur. I couldn't believe the outstanding quality and durability of these units. I also noticed how EXPENSIVE parts are for it! WOW! Parts for my truck are cheaper!! AND IT WEIGHS A TON!! Now its time to start planning the installation. Fun. Fun.







i picked up my onan in a trade, i traded a 4000 recoil start generick i picked up for $150 for it and it is a 4000 watt looks just about the same as your's to and yes they do weigh a ton!
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Old 10-31-2010, 07:56 PM   #182
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Re: CHANGED AGAIN! THIS WILL BE IT!!

Lately I've been working on getting the generator installed. Boy this sucker is heavy!!!! Its about 315 pounds!!

First of all I cleaned it and painted it. After searching on the web, I found a post on Smokstak that mentioned Napa carries a close match to the Onan green. Even had a part number!! Got it mixed and sprayed it on with my paintgun

Next I cut the opening. Generator frame is sitting on the ground.

This is the method I used to get the generator out of my work (I painted and cleaned it there) and get it to my house. My buddy runs a school bus company down the street and we borrowed a wheelchair van and used the lift.

Here we are sliding into place on the generator frame.

Here she sits in her new home

Next I decided to try to make it a little quieter. So I undercoated 3/8" plywood and used drywall screws with fender washers to attach insulation I got from harborsupply. This stuff is real thin so you have to layer it. But it was $30 for 25 feet which is quite cheap.

Here is a finished piece.

And the other pieces

And here are the pieces attached to the frame


Also installed an exterior recepticle. This will come in handy!

Recepticle and 12volt accessory outlet installed next to bench seat

New ONAN/CUMMINS OEM muffler and tailpipe installed. I had a local exhaust shop custom make the pipe


So generator is installed, wired, running and operational. Powers all systems.

I'm thinking of maybe taking advantage of the decent weather here in New England right now and start some exterior prep for paint. I need to replace rotted rub rails, get rid of old adhesive, lettering etc... etc....

More to come soon!!
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Old 11-01-2010, 08:13 PM   #183
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Re: CHANGED AGAIN! THIS WILL BE IT!!

Yeah Smitty.. Thats what I have on the tailpipe end. I really don't even need that strap around the muffler because that end of the muffler is vertically attached to the down pipe coming from the manifold. I just did it for a little extra support.
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Old 11-10-2010, 09:28 PM   #184
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Re: CHANGED AGAIN! THIS WILL BE IT!!

I started some exterior sheetmetal and prep work. The sheetmetal panel around the battery box was rotted at the bottom so I decided to replace the entire panel. I believe the thickness of the original sheetmetal is 16 gauge. The local steel supply did not have it so I got 14 guage which is thicker. A little harder to work with. But will last longer.

Here is how it was done.


This is the original panel that was rotted


First we started with our 4x8 sheet of 14 gauge

Then took the original panel and put it against the new metal and spray painted the edges creating an outline

You will notice there is no line on the top. This is because I had to make it about an inch higher to be able to create the original bend on the bottom. (new piece is being traced and cut upside down)


This is the back side of the new piece cut, and undercoated. The grey dot is the cutout for the intake heater plug.

Front side primed
This is what the area looks like with the panel taken off.

New panel in place! Can't wait to get it painted. The grey does not look good next to the yellow.

This is what some of the rubrails looked like that I took off. I figured I need about 35 feet of new rubrail.

This is the sheetmetal under the lower rubrail on the passenger side front

I just decided to cut the rusted area off instead of replacing the entire panel. This would have been a lot more work than the battery box panel.
I have a new piece riveted on. But forgot to snap a picture. I'm sure you can figure out what it looks like.

I will be replacing some sheetmetal in a couple more small spots and then prep, prep, prep.

These are some ideas for paint
I think this is my favorite.





How about something real crazy! LOL




Feel free to give me some other ideas for colors or designs!!
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Old 11-11-2010, 08:24 AM   #185
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Re: CHANGED AGAIN! THIS WILL BE IT!!

thats really nice metal work, what did you use to cut the sheet metal with?

tks
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Old 11-11-2010, 06:06 PM   #186
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Re: CHANGED AGAIN! THIS WILL BE IT!!

Believe it or not. An angle grinder with a cutoff blade. I've been using that for everything!
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Old 11-12-2010, 07:59 AM   #187
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Re: CHANGED AGAIN! THIS WILL BE IT!!

Really nice job!
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Old 11-12-2010, 08:59 PM   #188
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Re: CHANGED AGAIN! THIS WILL BE IT!!

Thanks guys.
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Old 11-13-2010, 03:12 AM   #189
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Re: CHANGED AGAIN! THIS WILL BE IT!!

Quote:
Originally Posted by BUSBOZO
Believe it or not. An angle grinder with a cutoff blade. I've been using that for everything!

Good call... I cut a ton of stuff with mine... I've gone thru a few harbor freight grinders though...
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Old 11-13-2010, 11:14 AM   #190
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Re: CHANGED AGAIN! THIS WILL BE IT!!

Nice job.

But wait...they call the paint on that genset GREEN?!?! Looks BLUE to me!
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