On 18 Jul 2004 20:52:56 -0700, (Robert Snyder)
wrote:

===I have seen where people have converted old motors into generators. I
===was thinking that would be a fun project and if I started with an old
===generator should be even better.
===
===I picked up (bought) a 4200W Coleman Generator with bag motor (piston
===through the block). I thought the generator and engine were seperate
===so I could add a different engine with maybe a coupling change. Not
===so.
===
===After getting the unit home and disassembling, I discovered the rear
===engine bearing (the crackshaft extents into the generator armature)
===was also the generator front bearing support. So after removing the
===engine the generator has no front bearing.
===
===So far I have the cost of the unit plus 3 hours time invested.
===
===The cost to replace the engine would be too high. I could probably
===buy a new generator for not much difference.
===
===I am considering making an armature shaft extension and adding a new
===bearing and support. I have Sears 6.6HP lawnmower engine to drive the
===generator. This could be via belt or direct connection. Not sure if
===the 6.6 is too small since the orginal engine was 8hp. Hopefully I
===will get at least 3kw with a 6.6. I have a small lathe and mill dril
===for making the adapter and bearing support.
===
===The generator needs to turn CW as a viewed for the engine connection
===end.
===If I use a simple belt drive, the generator would run backwards from
===its orginal setup. I can go direct couple if I hang the generator
===below the engine (not good because the outlets are on the rear of the
===generator. The engine runs CCW looking from the output shart towars
===the engine.
===
===Any suggestions would be helpful.


Have you actually checked on a replacement engine or shortblock from
Tulsa Small Engines or Small engine Warehouse? A lot of times they
have these engines for less than the price of dirt.


I have seen one ingenious individual salvage a gen set that had a
severely scored connecting rod journnal and piston. He removed the
piston and con rod, and bolted a section of the con rod on to the
crank shaft so it still had a slinger, removed giovernor and valve
train, and installed a pulley n the magneto side of the flywheel which
he drove with another common horizontal gas engine by way of a V belt.
It worked and worked fine, was a bit cumbersome when it came to moving
aorund but it provided power and all it cost him was time. He had
comtemplated making a plate with a bearing for the gen front support
but there was very little in the wya of shaft to work with an this was
his easiest way out. The internally stripped engine on this gen set
functioned mainly as a bearing support and driveline component.

The majority of all gen sets use a very short taper on the end of the
engines crank, so its not a odd ball setup.
Visit my website: http://www.frugalmachinist.com
Opinions expressed are those of my wifes,
I had no input whatsoever.
Remove "nospam" from email addy.