A few years ago my father traded generators with me. I gave him my 5000 Watt Coleman and he gave me his 6000 Watt Powerback. Hurricane season is here and I realized I had not done much with the generator since owning it. There were a few problems and I spent a couple of days fixing them:

One of the main problems with the generator was that it always cut off several times while running it. It would run dry for some reason but I never quite understood what was causing it. I started looking around while testing it and I noticed that there was something in the tank. It looks like a design flaw where they made the gas cap lid gasket out of something that falls apart easily. I rinsed the gasket material out and solved the problem:

The generator has and electric push button starter but the battery was always dead so I used the pull rope to start it. I wanted to install an old battery I had out of a Miata but the generator had ring terminals on it (for a small motorcycle battery):

I paid about $3 each for these post terminals and used them as adapters:

The last project was the largest. The generator was incredibly noisy and it was just too much to take. I wanted to quiet it down a bit so I looked around to see what I had. I found an old Miata exhaust system in my "junk yard":

I worked with the Miata exhaust a bit and after three trips to the parts store I didn't like the direction in which the project was going. I had a huge assortment of adapters, flex piping and exhaust clamps. I stopped for the night and the next morning pulled out a small muffler I had laying around for a few years:

Since I was using a different muffler I headed to the parts store again but this time I only needed two 90 degree bends and a 2.5" ID to 2.5"OD adapter:

I removed the small stock muffler and welded my adapter to it. I wanted to make the new exhaust system removable for easier storage so I kept this as a slip fitting and made sure it did not stick out very far:

You can see the holes in the stock muffler inside the adapter. There were a few other holes on the outside (not in the a circle pattern) so I put a little bead on each of them:

With the adapter welded on I slipped the first 90 bend in the new muffler and did a test fit:

Looks good but I will definitely need an exhaust hanger to keep my welds from breaking. Since the motor is mounted on rubber (doesn't move with the frame) I needed to use a rubber hanger for the downstream side of the system as well:

I found an old rusty mounting bracket and rubber hanger in the junkyard. Storage space is at a premium so I don't want the bracket sticking out any further than necessary:

Just enough room left to slip on the rubber hanger:

I also needed to fabricate a bracket for the muffer. I found an old piece of rebar and bent it into shape. Since I didn't want the rubber hanger to slip out of it from all of the vibration I welded a ball at the end of it:

The new bracket is welded to the muffler:

The new bracket and hanger system is complete:

Eventually I want to use the second 90 degree angle to mount a long pipe pointing straight up to get the sound above my head. For now I will just use it to direct the sound around to the back of the generator:

What the finished product looks like:

A view from the front:

So how does it sound? Well, it was really hard to capture the difference in the volume of noise coming from the stock muffler vs the car muffler. There is definitely a noticeable difference though (it just doesn't come through very well on the recording). The sound is different now as well. It is not as harsh and you can hear the engine mechanicals instead of horrendous exhaust gurgle. Also, the new muffler has cut down on some of the pulsing the engine was making: