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Open Roads Forum  >  Travel Trailers  >  Modifications and Accessories

 > DIY generator box for a honda 3000

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RoyB

King George, VA

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Posted: 04/19/16 12:46am Link  |  Quote  |  Print  |  Notify Moderator

I guess you don't have any overheating problems for the generator running inside the closed up box. I do see your vents and fan to move fresh air around... I guess your fan just plugs into the generator socket haha...

My 2KW Honda sets secured to the inside of my truck which has a lockable hard folding plastic FOLD-A-COVER bed covers and tailgate.

[image]

With my setup I only need to run my small generator three hours each morning usually during breakfast running my on-board PD9260C Converter/charger unit to recharge my 50% charged state battery bank back up to its 90% charge state in a three hour period.

We will make coffee for the day stored in a thermos during this three hour generator run... The only takes less than five minutes to grind and brew a 10-Cup capacity.. Can also use the microwave during this time as well... The rest of the items we run comes from the batteries and 600WATT PSW Power Inverter...

Everybody at the camp sites are always asking in the evenings how are you guys doing this with our trailer area all lit up , HDTV running, Ham Radio going, etc... and no generator noise....

We are setup to run all we want running when camping off the power grid running from our very quiet battery bank. I have to drop the tailgate and move my generator out onto the tailgate when doing this. Then just plug the trailer shore power cable into the generator 120VAC receptacle. This is our routine at 8AM each morning haha... Everyone else at the camp site gets to run their generators at this time as well - like an alarm clock...

My generator goes where we go - Never left unattended at the camp site...

Been using the Out of sight - Out of mind routine for several years now with my 2KW Generator setup.

Here on the East side of the USA we are constantly running into generator run time restrictions. Not many dispersed camping locations here...

When I finally get some added solar panels I will be able to cut the generator back to only an one hour run time and then the solar panels can complete the battery charge during the rest of the high sun day...

The Air conditioning is about the only high wattage toy we do without when camping off the power grid... Fans do just great at night for us...

Roy Ken

* This post was edited 04/19/16 12:57am by RoyB *


My Posts are IMHO based on my experiences - Words in CAPS does not mean I am shouting
Roy - Carolyn
RETIRED DOAF/DON/DOD/CONTR RADIO TECH (42yrs)
K9PHT (Since 1957) 146.52M
2010 F150, 5.4,3:73 Gears,SCab
2008 Starcraft 14RT EU2000i GEN
2005 Flagstaff 8528RESS


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Hemet

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Posted: 04/19/16 01:07am Link  |  Quote  |  Print  |  Notify Moderator

I built the APU box in the video below for two Smarter Tools units, would work for Honda and Yamaha. Also is installed on the carrier over the propane tanks.

https://www.youtube.com/watch?v=-_YPKs4dUqE

proxim2020

Houston

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Posted: 04/19/16 07:23am Link  |  Quote  |  Print  |  Notify Moderator

I used those same fans in the box I built for my Champion 3650. I used a pair of 12" fans and man do they move some air. I got a lot of hours on them and they've been through some severe conditions. My box averages about 5-10 degrees over ambient. It wouldn't be a bad idea to wire in a high temp cutoff switch if the generator doesn't have one built in. Just in case the fan stops running. With mine I was able to tap the low oil sensor output and wired in a NO temperature switch. If the inside temperature gets over 130 degrees, it kills the generator.

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Posted: 04/19/16 07:49am Link  |  Quote  |  Print  |  Notify Moderator

Proxim, that's a good idea. Also thinking of painting the lid white

When the clouds part, I'll run a test to check the running temperatures. I do know from measuring, the temperature in the back of a Line-x coated pickup truck bed is quite higher on a bright sunny summer day in the south.


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dtappy3353

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Posted: 04/19/16 12:03pm Link  |  Quote  |  Print  |  Notify Moderator

FWIW...I purchased the large black box also, remodeled it with access doors, large venting on intake with 12" fan on exhaust.

Here was the outcome:

1. These inverter/generators need a ton of air circulation with both intake and exhaust.
2. The exhaust fan eventually burned out (melted) and quit with the excessive heat even with top of enclosure open.
3. Outdoor temp was only 92. Inverter/generator is a Champion 3100. Genny overheated and quit.
4. All camping trips after that experience....we take Genny out of box and just leave it in back of truck while running. (would like to be able to have a cover of some sort while sitting in truck bed).
5. Have tried numerous times operating Genny inside of box however, it cannot seem to function with enclosure.
6. Exhaust is not modifiable.
PS. Champion 3100 also runs my 15K btu ac. while in eco-mode.

In my circumstances, pretty was not practical!

Please let me know if I've left something out.

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Posted: 04/19/16 01:03pm Link  |  Quote  |  Print  |  Notify Moderator

I know I am taking a risk, but tried to make it as close to the factory design as possible.

1- The intake fan is 665 cfm as factory spec.
2- The fan is on the intake side so it runs cooler, The closed lid helps with air flow past the genny. The open lid doesn't give as much flow over the genny.
3- Temps here will be much higher on an average spring day. I've measured the bed of the truck at 120ºF in August.
4- The hondas trip the breakers at high heat when running.

It will be in the 80's later this week. I'll leave the genny on the black driveway while it powers the TT air conditioning. We'll check the operating temps with my laser ray gun.

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Posted: 04/19/16 08:34pm Link  |  Quote  |  Print  |  Notify Moderator

Had a late night stroke of common sense; to add a hole in the side located as to hold the funnel for adding oil. The funnel should fit in the space next to the genny.

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Posted: 04/21/16 07:15pm Link  |  Quote  |  Print  |  Notify Moderator

A video of the genny in operation with temperature readings

Click here

proxim2020

Houston

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Posted: 04/22/16 07:43am Link  |  Quote  |  Print  |  Notify Moderator

I like it. I put my fans on the exhaust side. I was worried that putting the fans on the intake side could unintentionally create a bottle neck at the exhaust exit. In that situation heat would start to stack up. Not trying to give you advice, just something to think about if your temps rise too high in the summer heat.

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Posted: 04/22/16 05:18pm Link  |  Quote  |  Print  |  Notify Moderator

Thought about that too. But decided to go with the factory design. Seems to keep the breaker / outlet side of the box 40 degrees cooler. Today I tested it in 85 degree heat. Will post the video when it finishes uploading.

Can you take temperature readings while yours has been running ?

I'd really like to compare to a $1200 factory mode, thinking the metal would be a better conductor of heat to the breaker side which might bring up the temps on that side.

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