Ultimate Guide: Under Hood Installation of a 5500 Watt Generator

Ultimate Guide: Under Hood Installation of a 5500 Watt Generator

Table of Contents:

1. Introduction
2. Background of the Yard Car
3. The Need for a Generator
4. Disassembling the Generator Head
5. Modifying the Crankshaft
6. Fabricating a Face Plate
7. Cleaning and Machining the Face Plate
8. Assembling the Generator
9. Next Steps: Making Bracketry for Installation
10. Conclusion

Introduction

In this multi-part series, we will explore the process of repurposing a yard car and transforming it into a functioning vehicle equipped with a generator. This project entails disassembling and modifying a generator head to fit under the hood of the yard car. Part one will focus on disassembling the generator head and determining the necessary modifications.

Background of the Yard Car

The yard car, although no longer suitable for road use, remains an essential tool for various yard work tasks. To enhance its functionality, we aim to incorporate a generator into its design. This generator will power various tools and equipment, making the yard car even more versatile and efficient.

The Need for a Generator

While the yard car boasts useful features such as a solar battery maintainer, chains on the wheels, a hoist, and a winch, it lacks a generator. Adding a generator to the yard car will provide a reliable power source for running tools, welding, and other necessary tasks that require electricity. Therefore, the focus of this project is to dismantle a generator and adapt it to fit under the hood of the yard car.

Disassembling the Generator Head

The first step in the process is to remove the generator head from the main body of the generator. To create space for disassembly, we will start by pulling off the panel from the tank. This will allow us to visualize the connections between the generator head and the engine. Upon inspection, it becomes clear that removing the main part of the generator is necessary to access the bolts holding the end cup to the engine.

Modifying the Crankshaft

In order to adapt the generator to fit under the hood of the yard car, modifications to the crankshaft are required. We will need to remove the existing bearing in the outside of the crankcase and replace it with a ball bearing. Additionally, part of the crankshaft will need to be cut off and a pulley will be mounted to the end of the shaft. These modifications will allow the generator assembly to function properly as part of the yard car engine.

Fabricating a Face Plate

To ensure a secure installation of the modified generator, a face plate needs to be fabricated. Initially, the flywheel from the engine was considered, but due to the amount of material removal required, an alternative option was sought. A suitable candidate was found in one of the castings for the drive pulley of an engine-driven welder project. This casting can be machined to fit the generator's bearing and serve as an ideal face plate.

Cleaning and Machining the Face Plate

Before proceeding with the fabrication of the face plate, the casting needs to be cleaned and machined to the appropriate specifications. Using a lathe, the face plate will be shaped and the necessary features will be machined to accommodate the bearing and allow for proper installation. This step is crucial in ensuring a secure and functional connection between the generator head and the yard car engine.

Assembling the Generator

Once the face plate is fabricated and the necessary modifications are complete, the generator can be assembled. The spacer, shaft, bearing, and end cap will be carefully assembled to create a functional generator. However, certain adjustments, such as making the keyway deeper and drilling a hole in the end for a bolt to hold the pulley, may still be required.

Next Steps: Making Bracketry for Installation

In part two of this series, we will focus on making the necessary bracketry to securely install the generator under the hood of the yard car. This step will involve utilizing a CNC plasma cutter to create precise and custom brackets. While the completion of the CNC plasma cutter project will be addressed in a separate video, the fabrication of the brackets for the yard car installation will be showcased in part two.

Conclusion

Part one of this multi-part series has provided an overview of the process involved in repurposing a yard car by installing a generator. Through disassembling the generator head, modifying the crankshaft, and fabricating a face plate, significant progress has been made in transforming the yard car into a functional vehicle. With the generator assembly complete, attention will now shift to creating the necessary bracketry for installation in part two of this series.

Highlights:

• Repurposing a yard car to enhance functionality
• Installing a generator for reliable power source
• Step-by-step disassembly and modification process
• Fabricating a custom face plate for secure installation
• Utilizing a CNC plasma cutter for bracketry creation

FAQ

Q: Can the yard car still be used for road transportation? A: No, the yard car is no longer suitable for road use and serves as a dedicated tool for yard work.

Q: What tools and equipment will the generator power? A: The generator will provide electricity for running tools, welding, and various other tasks that require power.

Q: How will the generator be installed under the hood of the yard car? A: Custom bracketry will be fabricated to securely install the generator under the hood of the yard car, ensuring proper functionality.

Q: What modifications are required for the crankshaft? A: The existing bearing in the outside of the crankcase needs to be replaced with a ball bearing. Additionally, part of the crankshaft will be cut off to mount a pulley.

Q: Will there be further modifications or improvements to the yard car in the future? A: Part two of this series will focus on making bracketry for installation, which may involve additional modifications and improvements.