Custom built Generator Shelter

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Well It's been a loooooong time since I got back over here. I've been modifying and doing custom work on tractors lately and it took me away from the site for awhile. I recently did a little project for myself that I thought some of you might find half interesting so I figured I'd pop in a share it with you all.   Seems to me we are having more frequent power outages the last few winters. Last winter it went out for 11 hours and with no back up system it got cold in the house plus no way to warm a meal so with winter around the corner and not wanting to go through that again we decided to get us a generator. We went with a Honda 6500 model that has auto choke, electric start and I added a wireless remote to it. I got to thinking that you just can't through these things out in the elements when the power goes out so I decided to design and fabricate a shelter for it. Here's some of the features I built into it. - Built out of 1/8th and 1/4 steel plating. Complete system weighs 1500 lbs. - Custom machined hinges with grease nipples. - Built in security system. - Canarm fan for system cooling- Double stainless steel latches both coded for the one key. - Hydraulic struts to keep lid open. - Fold down front section that acts as a loading ramp for the generator. - Special locking system in floor to hold generator in place. - Custom exhaust system with top flapper. - Wireless remote start added. - Snap-On L.E.D. light added. - Floor mat that chemical resistant. - All openings have restricters added to keep critters out. - Sand basted to remove mill-scale, epoxy primed and painted. - Custom graphics by Kathy (Wifey) - G.P.S. Tracking on generator. - Pour a concrete pad to bolt it too.Very quiet operation although I shouldn't have used the sensitive directional mic in the video. Last edited by 4shorts; 10-09-2013 at 07:50 AM.Miller 302 Trailblazer/Custom TrailerMillermatic 350P/Spool gunMillermatic 252Miller Spectrum 875Miller Dynasty200DxHypertherm Powermax 85Tracker CNC 4X8 Pro Table (Down Draft)Visit us @ www.specialtyrepairscustommods.com
Reply:Some more photos. Miller 302 Trailblazer/Custom TrailerMillermatic 350P/Spool gunMillermatic 252Miller Spectrum 875Miller Dynasty200DxHypertherm Powermax 85Tracker CNC 4X8 Pro Table (Down Draft)Visit us @ www.specialtyrepairscustommods.com
Reply:Looks impressive!
Reply:Great fabrication work and looks weathertight and bug resistant.But, uh, where's the wire to the house?Be wary of The Numbers: Figures don't lie,. but liars can figure.Welders:2008 Lincoln 140 GMAW&FCAW2012 HF 165 'toy' GTAW&SMAW1970's Cobbled together O/A
Reply:4shorts, really nice fab work and attention to detail!  Just wondering how you connected the exhaust up?  With the work involved with building a pad for this genset to rest on, why did you not trench and lay pipe and wire to house?  That would have completed the job.  Not finding any fault with your work mind you, just saying.  Best  Bob
Reply:Your fabrication skills just amaze me. Again first class work! Don’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:Thanks guys. The reason for the concrete pad was I wanted the shelter elevated a slight bit just in case we had a Hugh amount of rain in a short time and it put me just above grade with the driveway so the front loading ramp would work well. It also gave me something substantial to bold the shelter too. Although theft isn't a big problem in our area why make it easy for someone to go off with it. Right now If we need to run the generator I have a drop cord that will plug directly into the house. I really didn't want to dig up my already paved driveway to bury a cord. So far this year we've lost out power twice. Once for 11 hours and the other was 4 so it's not like it's happening every day. Having it this way I can use the generator for other jobs if needed as well. As for the exhaust. I just made a simple adapter to go up against the OEM muffler.  Once the generator is in place the adapter can't detach from the exhaust.    Miller 302 Trailblazer/Custom TrailerMillermatic 350P/Spool gunMillermatic 252Miller Spectrum 875Miller Dynasty200DxHypertherm Powermax 85Tracker CNC 4X8 Pro Table (Down Draft)Visit us @ www.specialtyrepairscustommods.com
Reply:Great work as always Paul (and Kathy ). I too would love to see the engine-to-enclosure exhaust setup detail.  I could see the "bell" on the pipe inside and would guess it's a slip fit configuration.  How tricky/difficult is it to get connected while positioning the unit? Originally Posted by mike837goBut, uh, where's the wire to the house?
Reply:Nice clean design...great hinge setup...
Reply:That is really beautiful work But around here it just screams........STEAL ME!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!  !!All of the oilfield service trucks carry torches as part of the tooling, and those guys always need dope money"Any day above ground is a good day"http://www.farmersamm.com/
Reply:"...just manual back feed breaker and open the MAIN"That is sooooooooo illegal!I've studied the issue and it is exactly the method I use.Be wary of The Numbers: Figures don't lie,. but liars can figure.Welders:2008 Lincoln 140 GMAW&FCAW2012 HF 165 'toy' GTAW&SMAW1970's Cobbled together O/A
Reply:Originally Posted by duaneb55Great work as always Paul (and Kathy ). I too would love to see the engine-to-enclosure exhaust setup detail.  I could see the "bell" on the pipe inside and would guess it's a slip fit configuration.  How tricky/difficult is it to get connected while positioning the unit?
Reply:Great job, very pro! I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Oh I forgot to mention that although not completed yet I will have a waterproof plug  (pictured) on the house that the line with plug into then with a twist its locked in place. Inside next to the main panel there will be a lockout panel installed.  Over the last few years I've done a few more fabrication, welding and restorations so if anyone is interesting in that sort of thing we have a new web site up so your welcome to check it out at www.specialtyrepairs.ca Attached ImagesMiller 302 Trailblazer/Custom TrailerMillermatic 350P/Spool gunMillermatic 252Miller Spectrum 875Miller Dynasty200DxHypertherm Powermax 85Tracker CNC 4X8 Pro Table (Down Draft)Visit us @ www.specialtyrepairscustommods.com
Reply:Great work, looks top notch. The only thing I would of added is a gas can holders or a refueling tank on the side.PROUD   AMERICAN
Reply:Originally Posted by mike837go"...just manual back feed breaker and open the MAIN"That is sooooooooo illegal!I've studied the issue and it is exactly the method I use.
Reply:Turned out great. You know the power will never go out now that you have a generator. When I installed mine following an extended outage it was another 5 years before I needed it.
Reply:Hi Paul, Really nice to see you and your posts again, What can I say "Superb" Definitely thinking out side the box, Lets just hope you and your wife do not have to use it too often,Do I hear a touch of an Irish accent on the excellent video, Like all of your fabrications,something to be truly proud of.Lincoln SP-170 MigHypertherm powermax 45Lorch T220 AC/DC TigButters FM 215 synergic MigKemppi 180 adaptive mig RULES ARE FOR THE OBEDIENCE OF FOOLS AND THE  GUIDANCE OF WISE MEN.
Reply:Originally Posted by tackitPaul I would like to add one more thing..  I replaced the motorcycle batteries in my generators with auto batteries, I bought battery boxes from NAPA, now their starters will spin the 16 HP B&S Vanguard motors even when the temps get down to zero. tackit
Reply:How high does your snow get ?I might have put the vents as high as possible on the side to keep the snow from plugging the airflow.
Reply:One of the things I like, aside from the excellent work, is that it looks similar enough to the power companies boxes that many thieves would not even look twice at it .Nicely done on many levels Dave J.Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:Originally Posted by 7A749I expected it to transform into something like Optimus Prime when not in use...
Reply:Just one more thought...You'll want to exercise the generator once-a-month or so to keep the residual magnetic field in the armeture up and recharge the battery.There is almost nothing worse that a running generator that is putting out zero electricity!Be wary of The Numbers: Figures don't lie,. but liars can figure.Welders:2008 Lincoln 140 GMAW&FCAW2012 HF 165 'toy' GTAW&SMAW1970's Cobbled together O/A
Reply:Originally Posted by rlitmanAs for the battery conditioner, you could always get a solar one.
Reply:If it were me, I'd make a little padded milking stool with a beverage holder.  Then I could sit out there comfortably for hours and admire my work."USMCPOP" First-born son: KIA  Iraq 1/26/05Syncrowave 250 w/ Coolmate 3Dialarc 250, Idealarc 250SP-175 +Firepower TIG 160S (gave the TA 161 STL to the son)Lincwelder AC180C (1952)Victor & Smith O/A torchesMiller spot welderOriginally Posted by weldermikeGreat job, very pro!
Reply:I'm just gonna go ahead and blurt this out: This is probably the prettiest all around project I've seen on this forum in my nearly two years as a member.  It's my absolute favorite because it has it all for me: I love generators, it has exquisite fabrication, incredible design and detail, a sweet concrete pad, and a stunning paint job. Man, I'd probably mount a trailcam out there somewhere! Myself, my Generac 8000 is housed in a lousy lean-to...but it sure is nice when we lose power...especially in the massive blizzards we get. I also use it as a portable as it disconnects in seconds. On the subject of gen to house hookups...I backfed to my panel through underground cable and fabbed an interlock that prevents any possibility of being able to backfeed to the street. To engage the gen's breaker, the interlock kills the main. Has worked perfectly a hundred times. I also drove a 6 foot ground rod outside of my lean-to and wired it to a lug on my gens frame. Remote starter would be nice, though.POVERTY...is the Mother of InventionMillermatic 211Millermatic 140Miller Thunderbolt XLArcOne 100STS inverter w/TIGThermal Dynamics 38XL Victor Oxy/AcetyleneJancy Slugger Holemaker IIJet 5x6 BandsawNever enough time & sleep.
Reply:Great job.  I am impressed.  Richey
Reply:Oh I forgot to mention that I installed a manual  200 amp transfer switch to my generator near my homes outdoor disconnect box for a positive disconnect of my generator from the incoming power line.  Have put 120 hours on the 55kw generator in 14 years. Came in very hadn't year before last when all the tornadoes hit Alabama. We were out of power 2 weeks.  Thank goodness we had a generator. Mine is painted green like yours. I really like the remote starting. Richey
Reply:Great work. Subscribing to this thread.Hopefully in the near future, we will be out of this apartment and into a new home. Which will (unfortunately) be all electric. I have been reading up on back-up generators. I work in a generator rebuild shop and I dont know much about them other than how to weld on the panels. Last year we were without power for 9 days after a windstorm. After ours came back on my finance's parents were still without power for another 4 days. So they came to stay with us until it came back on.  Try to imagine 5 people sharing a 600 square foot, one bedroom apartment. If you cant fix it with a hammer, it must be an electrical problem."Boy, everyone starts with a full bag of luck and an empty bag of experience. The trick is to fill the bag of experience before the bag of luck is empty."-Grandad circa 1990ish
Reply:Hey, I recognize that fine work!  Good to see you over here too.
Reply:Originally Posted by SMC WeldcraftI'm just gonna go ahead and blurt this out: This is probably the prettiest all around project I've seen on this forum in my nearly two years as a member.  It's my absolute favorite because it has it all for me: I love generators, it has exquisite fabrication, incredible design and detail, a sweet concrete pad, and a stunning paint job. Man, I'd probably mount a trailcam out there somewhere! Myself, my Generac 8000 is housed in a lousy lean-to...but it sure is nice when we lose power...especially in the massive blizzards we get. I also use it as a portable as it disconnects in seconds. On the subject of gen to house hookups...I backfed to my panel through underground cable and fabbed an interlock that prevents any possibility of being able to backfeed to the street. To engage the gen's breaker, the interlock kills the main. Has worked perfectly a hundred times. I also drove a 6 foot ground rod outside of my lean-to and wired it to a lug on my gens frame. Remote starter would be nice, though.
Reply:I bought one of the cheap Chinese vibration hour meters($10) for my Champion generator but I quess my generator didn't vibrate enough for it to work all the time,I could flick it with my finger after I started my generator and it would start working but that wasn't good enough so I bought one similiar Chinese hour/tach meter($12) that hooks to the spark plug wire with 1 wire wrapped around the spark plug wire 3 or 4 turns and it works perfectly.I bought my Champion generator last year on Black Friday on sale and am real pleased with it.The hour/tach meter lets me keep up with oil changes plus the tach could be used for tuning the generator I quess.So the next time my electricity goes out for 2 weeks like it did during the ice storm of 2009/2010 winter I'll be prepared.By the way,nice generator shelter,good way to get it away from the house with the exhaust and keep it sheltered also. Attached ImagesLast edited by dugndeep; 10-10-2013 at 08:36 AM.Reason: more picsMaxus Pro-125 MigChicago Electric 90 amp DC flux-coreLincoln Electric AC 225 tombstoneO/A torchM/O mini-torch10 acres of flatland15 acres of holler
Reply:4shorts- that is a great build. I've thought of building something similarSMC- your interlock is genius!Safety 3rdGump
Reply:Originally Posted by dugndeepI bought one of the cheap Chinese vibration hour meters($10) for my Champion generator but I quess my generator didn't vibrate enough for it to work all the time,I could flick it with my finger after I started my generator and it would start working but that wasn't good enough so I bought one similiar Chinese hour/tach meter($12) that hooks to the spark plug wire with 1 wire wrapped around the spark plug wire 3 or 4 turns and it works perfectly.I bought my Champion generator last year on Black Friday on sale and am real pleased with it.The hour/tach meter lets me keep up with oil changes plus the tach could be used for tuning the generator I quess.So the next time my electricity goes out for 2 weeks like it did during the ice storm of 2009/2010 winter I'll be prepared.By the way,nice generator shelter,good way to get it away from the house with the exhaust and keep it sheltered also.
Reply:The company I work for builds custom enclosures for 500kw and up gensets.I've seen only a few small house genset enclosures.I am impressed with the design and thought process that you put into this!Around here a darker shade of green would make that look like a Utility transformer distribution box.
Reply:What a great job! Thank you for sharing all the little details. That remote will be nice when its Oh-Dark-Thirty and blowing hard. Just pull it out of the bedside stand....you won't even have to get out from under the covers. I was thinking the name of a Trash Company stenciled on the side would keep the thieves away. Ha! Of course it would be the cleanest dumpster ever seen!
Reply:Originally Posted by drujininThe company I work for builds custom enclosures for 500kw and up gensets.I've seen only a few small house genset enclosures.I am impressed with the design and thought process that you put into this!Around here a darker shade of green would make that look like a Utility transformer distribution box.
Reply:My son got a whole bunch of those plastic bags that have the biohazard logo on them.  He used to pack his lunch in them. "USMCPOP" First-born son: KIA  Iraq 1/26/05Syncrowave 250 w/ Coolmate 3Dialarc 250, Idealarc 250SP-175 +Firepower TIG 160S (gave the TA 161 STL to the son)Lincwelder AC180C (1952)Victor & Smith O/A torchesMiller spot welder
Reply:When you gonna build me one?...zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Awesome, it's your details and planning that always blow me away. Great work as always.....good to see you around again 4shorts!If you don't want to stand behind our Troops, feel free to stand in front of them.
Reply:the only thing missing is a bulk fuel tank and a transfer pumpVantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.
Reply:We  are without power sometimes too, ice and wind can snap off wooden poles by the dozen.Once it was a full week.No power, no water, no heat.I like the idea of generator power.How much fuel do you keep and how do you keep it fresh?Can you tell me more about the GPS trackers imbeded in the generator?I did a little searching and the ones I saw were all monthly subscription based.
Reply:Originally Posted by zapsterWhen you gonna build me one?...zap!
Reply:yes but nothing will annoy you like having to go out in a blizzard to refill the gasVantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.
Reply:Originally Posted by Dualieyes but nothing will annoy you like having to go out in a blizzard to refill the gas
Reply:Wow! That's incredible!