Re-insulating the generator compartment

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Re-insulating the generator compartment

April 28, 2013, 02:25:28 am

we're driveway camping at a friend's house in Prescott, and I just finished pulling the generator (8KW Isuzu) and re-insulating the compartment. As I did with the engine compartment, I used the foil-faced felt material that I got from MOT, and attached it over the old foam with 3M headliner spray adhesive and screws with fender washers for security. Edges were finished with aluminum foil duct tape. To reduce heat load, I also double-wrapped the exhaust flex pipe, and added fiberglass insulation behind the exhaust shield. Also pulled the gen off the base plate and refinished it, but had no time to send out for powder coating, so it's regular Rustoleum (phosphoric acid prep and primer, of course.)

Ran out of time to do the radiator frame conversion that Mark Z invented (Generator Radiator Modification), but it's still on the short list. (I verified that I can remove the floor under the gen pan if necessary to get access to the back side of the gen for that mod.)

I verified that with the flexible exhaust disconnected, there is just enough clearance to allow replacement of the rear bearing on the generator (alternator) without pulling the gen again. I was also concerned about brush replacement, but the tech at Power Tech said that my generator (1999 vintage) is brushless.

Not having any friends with fork lifts where we are (Prescott AZ) I borrowed an engine hoist (and the owner...), and there was just enough clearance between the hoist boom and the bottom of the generator door, so door removal (an option) wasn't needed.

It would have been great to be doing this on a concrete slab, but the situation was gravel with plywood on top, and it worked with some effort.

Disconnecting the flex exhaust, ground strap, and 12V cable to the starter was just possible for me squeezing in over the engine, but larger folks might need to remove the compartment floor for access.

Anyhow, all back together and working now.

I included a photo of the back side of the gen since that's a view that we don't often get.

Photos:

Re: Re-insulating the generator compartment

Reply #1 – April 28, 2013, 08:44:31 am

Nicely done! When I was at Power Tech a few years ago picking their brain and getting some parts one of their big recommendations is relocating the control box into the blower compartment to isolate it from heat and vibration. Their three most frequent jobs is that, the gen bearing and new motor mounts.

Re: Re-insulating the generator compartment

Reply #2 – April 28, 2013, 10:28:23 am

Dave, nice job. Do you think the generator is any quieter with the new insulation?

Re: Re-insulating the generator compartment

Reply #3 – April 28, 2013, 11:27:45 am

Gee, Dave! I get tired and sore just reading about all the great stuff you do.

Re: Re-insulating the generator compartment

Reply #4 – April 28, 2013, 04:18:40 pm

Dave,

Excellent job and many thanks for the step by step pictures (especially the backside) with instructions. The engine fork lift makes it possible even on gravel and insures a safe and relatively easy removal and replace. Did you replace the mounts while you had it out? My radiator shroud is loose and will have to be welded or I might go all the way and and do the fantastic radiator frame conversion by Mark Z. I'm not sure if the compartment on the Grand Villas are big enough to allow for this mod. It's a very tight fight fit when sliding the generator out and over time I'm sure one of the reasons besides vibration that causes the shroud to break loose and rub against the fan when when sliding in or out. Karma for you and Mark for all your efforts and sharing them in detail with the rest of us.

Dave Head,

Not sure about moving the control box to the blower compartment. Sounds like a good idea and do you know anyone who has done this? Would you have to pull the generator out to do it? I only want to pull the generator out one time for these jobs if possible.

Jerry

Re: Re-insulating the generator compartment

Reply #5 – April 28, 2013, 04:59:11 pm

FT Service has done it as a recommended mod for years.

Re: Re-insulating the generator compartment

Reply #6 – April 28, 2013, 07:07:55 pm

Dave,

very nice, this is on my to do list also

Re: Re-insulating the generator compartment

Reply #7 – April 28, 2013, 07:59:37 pm

Quote from: Kent Speers – April 28, 2013, 10:28:23 am

Dave, nice job. Do you think the generator is any quieter with the new insulation?

Don't think it is any quieter, but the bits of old foam aren't going to clog the alternator or engine radiator now! Also not embarrassing when I open the gen compartment now...

I have thought about lining the door with the good quality sound absorbing foam (easy and relatively cheap, since it's a small area.) We'll see. So nice not to be in danger of running out of projects!

Re: Re-insulating the generator compartment

Reply #8 – April 28, 2013, 08:11:37 pm

Quote from: coastprt – April 28, 2013, 04:18:40 pm

Dave,

Excellent job and many thanks for the step by step pictures (especially the backside) with instructions. The engine fork lift makes it possible even on gravel and insures a safe and relatively easy removal and replace. Did you replace the mounts while you had it out?

Thanks ! Having a fork lift would make it much easier, but doing it with an engine hoist on concrete wouldn't be too bad either. I considered replacing the mounts, but they were OK (may have been replaced by a PO). I did find that the little vibration mounts under the radiator were worn and not attached to the radiator at all ! Replaced them, but not clear that it improved things much. I think adding some mass to the bottom of the radiator shroud may be required... Gold bullion... depleted uranium... maybe a thick steel bar...

Re: Re-insulating the generator compartment

Reply #9 – April 28, 2013, 09:56:35 pm

The factory mechanic in Leesburg at their repair center about 1/2 mile from the factory.

Re: Re-insulating the generator compartment

Reply #10 – April 28, 2013, 10:31:11 pm

Nice job Dave. That is also on my list of things to do this summer. Thanks for all the info.

Mark

Re: Re-insulating the generator compartment

Reply #11 – April 28, 2013, 11:02:17 pm

Excellent Dave! I'm humbled in your presence.

see ya
ken

Re: Re-insulating the generator compartment

Reply #12 – April 29, 2013, 02:49:26 am

Thanks! But I'm humbled by all the other talent, skills and knowledge on this forum. An amazing collection of folks, and I'm grateful to be a part of it!

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Re-insulating the generator compartment

April 28, 2013, 02:25:28 am

Re: Re-insulating the generator compartment

Reply #1 – April 28, 2013, 08:44:31 am

Re: Re-insulating the generator compartment

Reply #2 – April 28, 2013, 10:28:23 am

Re: Re-insulating the generator compartment

Reply #3 – April 28, 2013, 11:27:45 am

Re: Re-insulating the generator compartment

Reply #4 – April 28, 2013, 04:18:40 pm

Re: Re-insulating the generator compartment

Reply #5 – April 28, 2013, 04:59:11 pm

Re: Re-insulating the generator compartment

Reply #6 – April 28, 2013, 07:07:55 pm

Re: Re-insulating the generator compartment

Reply #7 – April 28, 2013, 07:59:37 pm

Re: Re-insulating the generator compartment

Reply #8 – April 28, 2013, 08:11:37 pm

Re: Re-insulating the generator compartment

Reply #9 – April 28, 2013, 09:56:35 pm

Re: Re-insulating the generator compartment

Reply #10 – April 28, 2013, 10:31:11 pm

Re: Re-insulating the generator compartment

Reply #11 – April 28, 2013, 11:02:17 pm

Re: Re-insulating the generator compartment

Reply #12 – April 29, 2013, 02:49:26 am

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