I seem to jump from one sub project to another and today I am back working on the generator because I now dare to finish the fuel and electrical hook-ups since the compressor, air tank, generator gas tank and seats are more or less figured out (these items all overlap each other spatially). Jack
Now that we have internet service again, I'm enjoying your thread. Keep up the good work. My 1999 Gillig conversion is a somewhat different platform than you are working with, but I see that we are engaged in many similar issues. I'll be posting an update in the next couple days since I can do that now without having to go so elsewhere to join the web.
I do find it interesting that someone else has confessed to doing their best thinking in the shower. I find it a life-long habit. I've been known to spend hours wrestling with a thorny issue and go to bed disgusted, only to find the clear solution hovering in the steam of next morning's shower.
All the best with your bus and life.
"Who was that masked man?"
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- Joined: Wed Oct 07, 2009 3:13 am
- Location: western maine , the other alaska
the bus stopped and i got on and thats how it all began
I'm still working on the genny and it's remote wiring. I did get as far as starting it up today for a test run in it's "sound proof" drawer. While I am quite pleased with the noise level (not audable at 25 feet) I still have a ways to go with heat dissipation. I rigged the generator to shut down when its temp reached 184 degrees F and it did. I chose this temp baised on the heat range of the oil used in the genny which is 230 degrees F max. I ran my test using only one of the two fans available for cooling. Last night's shower produced the idea of moving the muffler out of the genny drawer and reinstalling it at the end of the flex exhaust pipe I have allready installed--that should eliminate a large part of the heat being trapped in the drawer and hopefully not increase the noise level. We'll see! Jack
On the topic of similar issues, I've spent a lot of time on my generator. It sat unused in my old motorhome for about five years. Took a good bit of effort to just get it running. I thought it was okay until I started using it to top the battery bank a couple weeks ago. When the MagnaSine inverter put a load on the genny, it was never able to hold a steady speed. I finally dug into the carburetor. It looks like this:
Turns out that the generators of that era came with a slightly different carburetor than the other Kohler KT 17s. It was not a big deal but time consuming. I had to make a couple gaskets that the local Kohler dealer told me did not exist. Genny is running fine now, but it would sound better mounted in the bus.
Heat is not going to be an issue in that installation. The space over the engine held the original air handler. With it out of the way, I have unlimited air flow. I think this photo will show what I mean:
This space is about 30" deep and the full width of the bus. The muffler takes some room on the left, and the air cleaner sits on the right wall. The middle area is open and most of the roof is open. All the heat should dissipate without problem. Sound, however, may be more of a problem. Our bedroom is on the other side of that wall, and right now it's just one layer of 3/4" plywood with with some sheet metal on most of the engine side. I have some ideas. We'll see if they work out.
I'm loving your bus. The old body is cool, and I'm a big fan of Isuzu diesels. My eventual generator will be powered by a four cylinder Isuzu out of a ThermoKing reefer. I can see why you would not want to mess up the look with panels on the roof, but for us, it's the only way to fly. One thing slowing me down on that end is that I refuse to drill through the roof unless absolutely necessary. Hope to soon have something to show on that front.
Good luck with the generator heat. Sounds like you're on the right track.
Jim in NC
The Lost Ranger
By the end of the day today, with the tally of 4 relays,3 thermocouples and 2 fans I saw the temp of the genny box drop from around 200 degrees to a balmy 128 degrees and never had a shut down (184 degrees oil temp) even after 3 hours of continuous operation . In the economy mode while standing next to the genny you can't tell it is running. At full bore when the second fan kicks in you are aware of the sound of rushing air but no genny noise. With the muffler out of the "sound proof" box you can hear it up to about 30 ft. I'll have to build a box just for the muffler and see if I can improve this aspect. I'll post some none-to-clear pics. Jack
My first trial run showed over 160 degrees cooling air temp--and an oil temp of 184 degrees as the unit shut down.
Generator electronics remote mounted out of genny box.
I'll use the original control panel to operate the genny. I added a fuel gauge to the cluster. [/]
View of genny box before tear down.
View of genny with ducting removed.
Genny out of drawer and apart to remove muffler.
Muffler out, genny back in box and a huge drop in temp.
Tango, You will appreciate this. I've spent my free time this week mocking up the cowl and fire wall to accomodate the turbo diesel. I doubt that you need worry about detailing your original fire wall because if it is anything like my bus you won't be able to use it anyway unless your engine and tranny are way farther foreward than mine. Ha Ha. My TD has an extra "intercooler" across the rear of the engine which cools the exhaust being directed to the EGR valve and interferes with the original fire wall. Hope yours is different! Jack
And, speaking of pedals...I picked up a '40's vintage "Speed King" bass drum footboard a couple of months ago that I'm gonna' try to use for my accelerator. Really cool old design, and it even has "Speed King" in raised letters across the top! Given my motor and the age of the bus, I just can't decide whether that constitutes irony, sarcasm or just plain wishful thinking. Thought I was being so clever and original with that idea but just the other night I was at may usual watering hole and stopped to look over a really classic T-Bucket roadster parked out front and damned if it didn't have exactly the same pedal! Oh well, at least '46 Skoolies are rarer on the road here than Buckets.
This is what the dash looked like before I began work on the fire wall
This is a view from the engine side less cowl.
Lightweight cardboard template with cowl.
20 gauge sheetmetal with pattern transfered.
First trial fit of sheetmetal. I'm sure there will be trimming to do but the brake pedal, gas pedal. steering and wires all seem to fit.
And I have to admit that like you...I like messin' with metal. Just wish I had your tools & skill! A plasma cutter would make for even more fun.
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