I just completed my "project" that I eluded to in some posts in this thread and in the Beginning RVing section.
If you recall I purchased a Wen PowerPro 3500 unit ($249.99) and rewired it according to the instructions on Page 90 (well, I did the simpler thing by wiring it directly to produce 120V 30A (actually 28A) only, IIRC those directions were around page 92 - Wyatt-S's post).
In any event, the next part of the project was to build a sound box with the intent to get the noise to that of an Honda e2000i or less and keep the temperature within operating specs of the unit (not more than 140 degrees interior).
So, after contacting Fleetwood to see what load I can put on my FW's bumper (I was assured that the bumper could handle up to 500 lbs.), I initially installed a bumper receiver hitch ($35.00) and attached the cargo carrier ($75.00). I then built the sound box using plywood and sound board to line it. That was created from plywood that I already had (no cost there) and sound board (MBX) and various parts. Cost there was approximately $55.00 including hardware - "L" brackets, screws, vent covers, etc.) With plywood, it might have come closer to maybe $75.00.
I mounted the generator inside and then took a test drive for weight.
Well, while the cargo carrier (75 lbs.), the sound box (36 lbs.) and the generator (appox. 100 lbs.) were well under the 500 lbs. static, driving produced a force in excess and I could see from the shadows cast that this would not work. I had to have a receiver hitch welded to the frame of my FW.
So, I had that done and mounted the unit onto the new receiver hitch ($230.00 complete). So far so good.
Now for the sound test.... I had the opportunity to camp with my fellow moderator, Tony (Firedude) back in February, who owns a Honda e2000i. We had talked about the project over the course of the year and he was very interested to see how it would turn out.
We first fired up his Honda and put it into eco-mode then stepped back. Sounded nice and quiet. We then put a load onto it and again stepped back. We also had a California State Park Ranger take part at one point to give us the "official's" word as to noise level. We now had our "standard."
We then started up my unit and stepped back. It was actually quieter than his Honda (when not in eco-mode). We applied a load, and it was no different (small amount of lugging, then back to normal).
We then looked at temperatures. With no vent holes (other than the exhaust pipe, a blower motor ($29.00) to bring in fresh air and an exhaust fan ($25.00), the temperature went high (to around 200 degrees F). That's no good. So, we started cutting vent holes in the cover. I was concerned that we were creating holes for the noise to escape as well, but figured, this was part of the project. We started with three holes and that helped a bit. We added three more and the temp was now down to around 160 degrees F. Still a bit high for my liking. The sound, however, was still quieter than his Honda (non-eco mode). I was pleasantly surprised.
So, we attached a vent pipe and cap to the blower motor to direct the incoming air directly over the motor ($30.00). I also added a second exhaust fan ($25.00).
That did the trick. We were now at 140 degrees F and still quieter than the Honda. We confirmed this with the park ranger who said that the noise level was very acceptable at the state parks.
I did replace the circuit breaker ($30.00) that came with the generator as when I applied a full load (air conditioner + microwave), it would pop the breaker. I also beefed up the wiring between the generator head and the outlets so that the wires could handle the full 30 amp load if need be (12/2 for 4 feet - 2 from the generator hot to the CB, and 2 from the CB to the outlets hot terminal, and 2 from the generator neutral to the outlets for the neutral terminal; the ground is grounded to the trailer chassis and to the outlets ground terminal).
Total cost for the project: $784.00 (that puts out 30 amps and is quieter than the Honda e2000i)
Cost of a Honda e2000i: $999.00 (that puts out 20 amps), you might be able to get it at $899.00 but I haven't seen it cheaper.
Cost of a Honda 3000i: around $1200.00 to 1500.00 (and louder than the two previous items).
The "cleanliness" of the output has already been discussed by another poster in this thread, and I'll tell you that the electrical output from this generator is cleaner than my own home's electricity.
So, finally, here are the pictures of the results.
If you recall I purchased a Wen PowerPro 3500 unit ($249.99) and rewired it according to the instructions on Page 90 (well, I did the simpler thing by wiring it directly to produce 120V 30A (actually 28A) only, IIRC those directions were around page 92 - Wyatt-S's post).
In any event, the next part of the project was to build a sound box with the intent to get the noise to that of an Honda e2000i or less and keep the temperature within operating specs of the unit (not more than 140 degrees interior).
So, after contacting Fleetwood to see what load I can put on my FW's bumper (I was assured that the bumper could handle up to 500 lbs.), I initially installed a bumper receiver hitch ($35.00) and attached the cargo carrier ($75.00). I then built the sound box using plywood and sound board to line it. That was created from plywood that I already had (no cost there) and sound board (MBX) and various parts. Cost there was approximately $55.00 including hardware - "L" brackets, screws, vent covers, etc.) With plywood, it might have come closer to maybe $75.00.
I mounted the generator inside and then took a test drive for weight.
Well, while the cargo carrier (75 lbs.), the sound box (36 lbs.) and the generator (appox. 100 lbs.) were well under the 500 lbs. static, driving produced a force in excess and I could see from the shadows cast that this would not work. I had to have a receiver hitch welded to the frame of my FW.
So, I had that done and mounted the unit onto the new receiver hitch ($230.00 complete). So far so good.
Now for the sound test.... I had the opportunity to camp with my fellow moderator, Tony (Firedude) back in February, who owns a Honda e2000i. We had talked about the project over the course of the year and he was very interested to see how it would turn out.
We first fired up his Honda and put it into eco-mode then stepped back. Sounded nice and quiet. We then put a load onto it and again stepped back. We also had a California State Park Ranger take part at one point to give us the "official's" word as to noise level. We now had our "standard."
We then started up my unit and stepped back. It was actually quieter than his Honda (when not in eco-mode). We applied a load, and it was no different (small amount of lugging, then back to normal).
We then looked at temperatures. With no vent holes (other than the exhaust pipe, a blower motor ($29.00) to bring in fresh air and an exhaust fan ($25.00), the temperature went high (to around 200 degrees F). That's no good. So, we started cutting vent holes in the cover. I was concerned that we were creating holes for the noise to escape as well, but figured, this was part of the project. We started with three holes and that helped a bit. We added three more and the temp was now down to around 160 degrees F. Still a bit high for my liking. The sound, however, was still quieter than his Honda (non-eco mode). I was pleasantly surprised.
So, we attached a vent pipe and cap to the blower motor to direct the incoming air directly over the motor ($30.00). I also added a second exhaust fan ($25.00).
That did the trick. We were now at 140 degrees F and still quieter than the Honda. We confirmed this with the park ranger who said that the noise level was very acceptable at the state parks.
I did replace the circuit breaker ($30.00) that came with the generator as when I applied a full load (air conditioner + microwave), it would pop the breaker. I also beefed up the wiring between the generator head and the outlets so that the wires could handle the full 30 amp load if need be (12/2 for 4 feet - 2 from the generator hot to the CB, and 2 from the CB to the outlets hot terminal, and 2 from the generator neutral to the outlets for the neutral terminal; the ground is grounded to the trailer chassis and to the outlets ground terminal).
Total cost for the project: $784.00 (that puts out 30 amps and is quieter than the Honda e2000i)
Cost of a Honda e2000i: $999.00 (that puts out 20 amps), you might be able to get it at $899.00 but I haven't seen it cheaper.
Cost of a Honda 3000i: around $1200.00 to 1500.00 (and louder than the two previous items).
The "cleanliness" of the output has already been discussed by another poster in this thread, and I'll tell you that the electrical output from this generator is cleaner than my own home's electricity.
So, finally, here are the pictures of the results.
