Mounting Mock Up

Work Day #2, Sub-Frame fabrication and mock up

Today's goal was to build a sub-frame to connect the engine and generator. I've received a lot of inquires asking if I would fabricate frames and couplings, and while I'm never adverse to making some extra cash, I will not make any commitments until I know exactly what I'm getting in to!

One of the interesting aspects of such a project (fabricating frames for other interested parties) is the variation in engine and generator mounting heights. Consequently I'm aiming for a simple sub-frame design that will allow easy alteration of the engine mounting height. To implement this idea, I started with some 2x3" 1/4" wall square tubing, and added some 3X3" angle iron to support the generator head. Next I fabricated and engine mount out 3x4" angle iron and attached it to the motor. To assist with the fine adjustment of the engine height (so the yet to be fabricated engine coupling will align with the generator shaft), I added some temporary threaded rods. Once I get the coupling fabricated, I'll use the threaded rods to get the engine height as close as possible, then weld the angle iron engine mounts to the square tube. If all goes well, I hope to avoid using an excess of shims.

At the moment, I'm waiting on new LoveJoy L150 jaw couplings to arrive, the previous set of couplings I had were the wrong bore size. Finding a vendor that stocks 48mm shaft couplings was a little bit of a challenge, but I finally found http://www.motionindustries.com. Unfortunately, the 48mm ID couplings were a special order item, so it appears it will take a few weeks to receive the couplings. In the mean time, I'm kind of at a stop. I can't proceed with sub-frame fabrication until I fabricate the engine coupling. I can't fabricate the engine coupling until I have the shaft couplings in hand. (well I could attempt the fabrication off published specifications, but I do much better work with hardware in hand!)

While I wait for the shaft couplings to arrive, I guess I'll start building the 220v, 65Amp electrical sub-panel. Once I receive the shaft couplings, I can fabricate the engine adapter, and finish the sub-frame, and see how well this thing works as is.

So until next time, I hope you enjoy the below pictures.

Mounting Mock Up