Increase the Power! DIY Generator Exhaust Extension Kit

Increase the Power! DIY Generator Exhaust Extension Kit

Table of Contents:

1. Introduction
2. Why Do You Need an Exhaust Extension Kit?
3. Choosing the Right Generator
4. Materials and Tools Needed
5. Step 1: Creating the Custom Flange
6. Step 2: Preparing the Surface for Silicone Application
7. Step 3: Applying the RTV Silicone
8. Step 4: Mounting the Flange to the Muffler
9. Step 5: Trimming the Exhaust Pipe
10. Step 6: Final Assembly and Testing
11. Conclusion

Article:

How to Make a Custom Bolt-On Exhaust Extension Kit for Your Generator

Introduction

If you own a generator and need to run it in your garage or RV camper, you may be concerned about the potentially harmful effects of the exhaust fumes. In this guide, we will show you how to create a custom bolt-on exhaust extension kit for your generator, allowing you to safely ventilate the exhaust steam without voiding your generator's warranty. By following these step-by-step instructions, you can ensure the safety of your family and the longevity of your generator.

Why Do You Need an Exhaust Extension Kit?

Running a generator in an enclosed space like a garage or a camper can lead to the buildup of harmful exhaust fumes. These fumes contain carbon monoxide, a poisonous gas that can be deadly in high concentrations. To protect yourself and your loved ones from this danger, it is crucial to properly ventilate the exhaust steam. However, modifying your generator's exhaust system without the right equipment can void its manufacturer warranty. That is why it is essential to create a custom bolt-on exhaust extension kit that allows you to safely vent the exhaust steam without compromising your generator's warranty.

Choosing the Right Generator

Before starting this DIY project, it is important to choose the right generator for your needs. Consider the power requirements of your appliances and make sure the generator you choose can handle that load. Additionally, choose a generator that is known for its quiet operation, as this will minimize noise pollution. Many generators on the market today offer both reliability and quiet performance, making them ideal for use in residential areas.

Materials and Tools Needed

To create your own custom bolt-on exhaust extension kit, you will need the following materials and tools:

• Permatex 650 degrees high-temperature red RTV silicone
• 1.5-inch diameter flexible exhaust repair kit
• 1-inch round floor flange
• 1-inch by 3-inch nipple
• 1-inch by 3/4-inch coupling reducer
• 2 M5 5.08 by 30-millimeter socket head cap screws
• Grinder with a cutoff wheel
• Drill with the appropriate bits for drilling through galvanized steel
• Drummel tool with a pointy stone bit
• Painters tape
• Protective eyewear
• Paper towels
• Razor blade

Step 1: Creating the Custom Flange

The flange is a crucial component of the exhaust extension kit as it provides a secure and airtight connection between the generator's exhaust system and the extension tubing. Start by tracing the mounting hole locations using the exhaust arrestor bracket that came with your generator. This will give you a general idea of where to drill your new mounting holes. Use a sharpie marker to sketch out the pattern on the floor flange surface and then use a grinder with a cutoff wheel to shape the flange according to your desired design. Take your time to achieve the final result and wear protective eyewear throughout the process.

Step 2: Preparing the Surface for Silicone Application

To ensure a tight seal between the flange and the exhaust muffler, it is important to prepare the surface of the muffler. Apply painters tape on the muffler's surface to act as a release film for the RTV silicone. Trace the flange pattern onto the painters tape using a sharpie marker. Cut away the tape in the screw hole locations to allow for easy bolt installation during the final assembly.

Step 3: Applying the RTV Silicone

The RTV silicone is used to create a sealing gasket that prevents exhaust gases from escaping. Apply a generous amount of silicone within the traced pattern on the painters tape. Don't worry about excess waste as it can be easily removed with a razor blade during the cleanup process. Make sure to only go as high as the middle point of the pre-existing exhaust pipe sticking out.

Step 4: Mounting the Flange to the Muffler

After allowing the silicone to cure according to the manufacturer's instructions, it's time to secure the flange to the muffler. Bolt down the flange using the mounting bolts and let it cure for a full 24 hours. This will ensure a strong and airtight seal between the flange and the muffler.

Step 5: Trimming the Exhaust Pipe

To complete the exhaust extension kit, you will need to create a new exhaust pipe using the coupling reducer and the flexible tubing. Apply RTV silicone to the smaller side of the coupling reducer and smooth it out with a paper towel. This will provide a flush and even surface for attaching the hose clamp bracketry. Trim the new mounting bolts to length, taking into account the additional thickness of the flange.

Step 6: Final Assembly and Testing

Once all the components are prepared, it's time to assemble the exhaust extension kit. Attach the flexible tubing to the coupling reducer and secure it with a hose clamp. Mount the exhaust pipe to the flange using the trimmed mounting bolts. Make sure everything is tightened properly. Finally, test the system by running the generator and checking for any signs of exhaust leakage. If everything is working correctly, you can enjoy the peace of mind of knowing that your generator's exhaust steam is safely ventilated.

Conclusion

Creating a custom bolt-on exhaust extension kit for your generator is a simple and effective way to safely use your generator in your garage or RV camper. By following the step-by-step instructions provided in this guide, you can ensure the proper ventilation of exhaust steam without voiding your generator's warranty. With the right materials and tools, you can easily create a customized solution that meets your specific needs. Stay safe and enjoy the convenience of backup power without the worry of harmful exhaust fumes.

Highlights:

• Learn how to create a custom bolt-on exhaust extension kit for your generator.
• Ensure proper ventilation of exhaust steam without voiding your generator's warranty.
• Choose the right generator for your needs, considering power requirements and noise levels.
• Use readily available materials and tools to complete the DIY project.
• Follow step-by-step instructions for creating the custom flange, applying the RTV silicone, and assembling the exhaust extension kit.
• Test the system for exhaust leakage to ensure its effectiveness and safety.

FAQ:

Q: Can I use this exhaust extension kit for any type of generator? A: The exhaust extension kit can be customized to fit most generators. However, it is important to choose the right size and type of components for your specific generator model.

Q: Is it necessary to use high-temperature silicone for this project? A: Yes, it is crucial to use high-temperature silicone to ensure that it can withstand the heat produced by the exhaust steam.

Q: Will this exhaust extension kit completely eliminate all exhaust fumes? A: While the exhaust extension kit is designed to safely ventilate the exhaust steam, it is still essential to operate the generator in a well-ventilated area to minimize any potential exposure to exhaust fumes.

Q: Can I install this exhaust extension kit myself, or do I need professional help? A: This DIY project is relatively straightforward and can be completed by most individuals with basic DIY skills. However, if you are unsure or uncomfortable with any step of the process, it is always best to consult a professional for assistance.

Q: Will using this exhaust extension kit void my generator's warranty? A: Using a properly installed exhaust extension kit should not void your generator's warranty. However, it is essential to follow the manufacturer's guidelines and ensure that the installation does not cause any damage to the generator.