Ecomod gasoline generator

[P-hack]

you can always add a "calibrated" induction leak, tapped into the exhaust maybe.

[oil pan 4]

I have since picked up a broken 7kw generator, and fixed it and re wired it.
Its got electric start, the riding lawnmower sized battery was dead, I had an optima battery collecting dust so I put that on there along with a pure sine wave 1000w inverter.
I think with a 1000w inverter on the generator, a 350w and 750w inverters on my LiFePO4 starting packs I should be good for powering small items efficiently.

The small coleman will be sold at some point since it cant power my smaller welding machines very well.

This large generator should be able to electrically power my plasma cutter with ease. That plus a gasoline air compressor and I can go off grid with my miller specrtum 625 plasma (a decent plasma that can cut 3/4 inchs of steel and clean cut 3/8 inch aluminum or stainless).

[oil pan 4]

The new generator can run my plasma cutter at nearly full power.

[Cobb]

So, how did you "eco" mod it? Just adjust the plug gap and added a cai?

Sounds like you may of raised or lowered the governed engine speed to raise and lower the volts.

Lastly, it sounds like the inverter is connected to the starter motor battery? Or is it connected to a battery and to the 12 volt charger circuit of the generator?

Any test results on actual fuel consumption, fuel to kw?

Just wondering as Ive used a small 800 watt one from harbor freight at half load. 4.5 hours. With old gas it runs about 3 hours. Unlike my stihl chainsaw, it seems to run on anything. The chain saw refuses to start unless its fresh gas.

The chain saw you ask? Its stock, works on 6-7 medium size trees before it needs a refill. I run it full throttle once the chain gets within half an inch of wood.

[oil pan 4]

The big generator is just going to run 3600rpm, the inverter will run off the starting battery and I will keep the 12 volt battery charger handy.
I have not tested fuel consumption.

[Cobb]

At the machine shop they use to get custom ground cams, use a piece of Plexiglas and emery cloth to mill the head on the old brigss n straton engines to make more power.Of course they were out for power, not saving gas. I guess you can mod a smaller engine for more power like a 3 hp in place of a 5 and mod it for more power and that will save?

[oil pan 4]

Actually more "power" from the engine would be a good thing.
The 7kw generator is rated to put out 29 amps at 240 volts. Problem is the plasma cutter uses 30 to 31 amps. The electrical portion can take that kind of power out put, but the engine rpms drop off, cant keep up.
I need to check apparent power on my plasma.
Yeah I can run it fine by turning it down a little, but who wants to do that.

Running a smaller engine harder does save gas.
My air compressor uses a real old 5 horsepower flat head briggs, if I bump compression it would make more power, with more power I could stick a larger pully on the engine and get more air out of the compressor. Maybe run 1 compressor instead of 2.

The 7kw generator has a new style Briggs and Stratton with an OHV engine. Bumping compresion isnt as easy.
The 1900w generator has a slightly newer version of the engine on my air compressors engine, the generator is rated for 18 or 19 amps but will hold a 22amp load no problem. So its good.

I am running into a basic fundamental problem where the rate of work I can do is limited by the horsepower output of my machines.

[Cobb]

Maybe a stupid question, but is it more economical or just convent to use a generator vs shore power?

Ive considered buying a generator to try my hand at welding and a contractor said our home was too old for a load like that and suggested calling the power company to get a new meter/service installed. Power company said they can give me up to a 440, but it will have a monthly fee rather I use it or not.

I kind of concluded I would buy a generator that doubles as a welder to try it. That way I got a generator too for power failures or maybe I can get 90% of my money back reselling it?

My smaller 400-800 watt generator was to run my fathers oxygen machine. We use it since he passed away for power failures and I use it to run electric yard tools vs plugging in multiple extension cords or buying one long extension cord.

[oil pan 4]

You dont need 440v power to run a home hobbyists welding machine.
Only really powerful machines can run 440.
If you can use an electric clothes dryer or electric cooking range you have more than enough power capacity to run any normal welding machine.
Welding generators are very expensive since they have both high voltage and low voltage arc welding windings. But 120 and 240 standard generators make poor power supplies for welding machines unless they are grossly over sized. A 2000 watt generator wont power welding machine that needs 2000 watts, not even close, I already tried it.

I have a sorry old 100 amp power service connection and use a fairly good size 230 amp arc welder no problem.

I have made very long, very heavy power cords for both standard 120 volt and 240/120volt power to avoid running the generator, because gas is expensive.

[Cobb]

Have you tried a new or heavier power cord? I use to use a generic orange electric cable to plug in my phev kit and it would take 4-5 hours to charge up. I use to plug it into a power strip by itself for extra safety.

Well, it tripped the braker on the strip and I went and purchased a 10 gauge extension cord. I found I cut my charging time in half. I also did a similar experiment with my 13 amp leaf vac. The lights blinked when I turned on the vac with a regular cord, with the 10 gauge it didnt. The vac held its speed better and didnt get as bogged down under load either.