DIY Generator Using Spare Parts

DIY Generator Using Spare Parts

Table of Contents:

1. Introduction
2. Purchasing the Husky Generator
3. Assessing the Blown Engine
4. Utilizing the Generator for Parts
5. Locating a Good Used Crankshaft
6. Finding a Husky Generator Frame
7. Checking for Necessary Spare Parts
8. Rebuilding the Engine
9. Dealing with the Bypassed Circuit Breaker
10. Double-Checking the Fuse and Wiring
11. Repairing and Straightening the Rail
12. Installing the Bell Housing and Rotor
13. Cleaning the Slip Rings
14. Securing and Aligning the Stator
15. Checking the Spark Plug and Rotor
16. Finalizing the Generator
17. Testing and Troubleshooting
18. Conclusion

Rebuilding a Husky Generator with a Blown Engine

Introduction

In this article, we will dive into the journey of rebuilding a Husky generator that was purchased with a blown engine. We will discuss the process of assessing the damage, finding replacement parts, and utilizing the generator for other purposes. Join us as we explore the steps taken to resurrect this generator and bring it back to working condition.

Purchasing the Husky Generator

A few months ago, the author stumbled upon a Husky generator with a blown engine. Despite not intending to fix the engine, they purchased it for the sake of acquiring spare parts. At a price of only $65, it seemed like a good opportunity to obtain valuable components.

Assessing the Blown Engine

Upon disassembling the engine and evaluating the extent of the damage, it became clear that a complete overhaul was necessary. The crankshaft, piston, and connecting rod were all in need of replacement, totaling around $300 in parts. Considering the modest selling price of a fully functional generator of about $400, the decision to salvage parts from this one seemed logical.

Utilizing the Generator for Parts

The power head of the damaged generator was repurposed to fix another generator with a faulty power head. The receptacle box found a new home in a generator with a malfunctioning circuit breaker. Even the frame itself was swapped onto a different generator that had suffered severe rust and damage. The unused components of the original generator were put to good use, giving new life to other machines.

Locating a Good Used Crankshaft

After some time, a good used crankshaft was finally found from another blown engine. With this crucial component secured, the engine could finally be rebuilt. Despite the condition of the rest of the generator, the author's determination to restore it remained strong.

Finding a Husky Generator Frame

By a stroke of luck, someone listed a Husky generator frame for sale at a mere $35. This was exactly what was needed to revitalize the project. The frame came complete with wheels, handles, and the necessary foot support. With the rebuilt engine and the available power head, the assembly process was ready to begin.

Checking for Necessary Spare Parts

Before delving too deep into the project, the author had to go through their collection of spare parts and ensure that everything required for a functioning generator was available. With the tank, heat shield, bolts, bell housing, brushes, engine mounts, and electrical box all accounted for, the missing circuit breaker became a minor obstacle. However, a potentially compatible one was found, and with some creative swapping, it seemed like a usable solution.

Rebuilding the Engine

With the engine rebuild completed and the various components gathered, the author began the process of putting the generator together. The intricate task involved meticulous wiring and precise placement of each part. It required careful attention to detail to ensure that everything was connected correctly and securely.

Dealing with the Bypassed Circuit Breaker

During the inspection of the circuit breaker, an interesting discovery was made. It appeared that the fuse had been bypassed, with the connections bridging directly without any interruption. Such a modification can be dangerous and may have contributed to the earlier engine failure. Understanding the potential risks, the author set out to rectify this issue by replacing the faulty parts and restoring the circuit breaker to its intended functionality.

Double-Checking the Fuse and Wiring

With the replacement fuse in place and the new circuit breaker installed, it was crucial to double-check the fuse's functioning and verify that the wiring was correct. The author meticulously tested each connection to ensure that the circuit breaker would trip appropriately, providing necessary protection to the generator.

Repairing and Straightening the Rail

One of the components that required attention was the rail on the stator side. It had suffered damage, causing a slight misalignment. The author carefully tapped and straightened the rail, ensuring that it was back in optimal condition. This step was vital for a smooth and efficient operation of the generator.

Installing the Bell Housing and Rotor

Next, the bell housing was securely installed using thread locker to prevent any loosening over time. The attention to detail ensured a stable structure for the generator. The rotor bolt, which had been lost temporarily, was located through careful searching and finally received, allowing the assembly to proceed.

Cleaning the Slip Rings

Before proceeding further, the slip rings were cleaned thoroughly. The author used a piece of Scotch-Brite to remove dirt and debris from the rings, being cautious to avoid damaging the wires within. The cleaning process was essential for maintaining optimal performance and electrical conductivity.

Securing and Aligning the Stator

The stator, a vital component responsible for generating electrical power, needed to be properly secured and aligned within the generator. Adjustments were made to the engine mounts, allowing for seamless integration of the stator. The careful placement and alignment of the stator would guarantee the efficiency and functionality of the generator.

Checking the Spark Plug and Rotor

At this stage, it was essential to check the spark plug and ensure that the rotor was not scraping against the stator. These tests were crucial to verify that the generator was ready for operation. The author meticulously examined each component, making adjustments as necessary to guarantee optimal performance.

Finalizing the Generator

With all the major components in place and functioning correctly, the generator was finally complete. The amalgam of parts from different generators had come together to form a fully functional and reliable power source. The author stood back, satisfied with their achievement, as the generator stood ready for the next phase of testing.

Testing and Troubleshooting

To ensure that the rebuilt generator was indeed functioning as expected, the author decided to conduct thorough testing. Starting with a basic check of the electrical system, the generator was subjected to various loads and situations to evaluate its performance. The author meticulously observed the generator, noting any irregularities or issues that needed troubleshooting.

Conclusion

In conclusion, the journey of rebuilding a Husky generator with a blown engine proved to be a challenging yet rewarding endeavor. Through careful assessment, resourcefulness, and a desire to repurpose parts, the author successfully resurrected a generator from what seemed like a lost cause. The generator, comprised of components from multiple machines, now stands as a testament to ingenuity and determination.