Some changes to the Doghouse
 

Here is what I did with my exhaust system, there is another one on the other side, in the same location. I ran all new from the turbo and used a y-pipe to slit the system up. The exhaust used to have a low droning noise that came up into the sleeper,...now I have to touch my wall to see if I can feel the engine run.When I first went out the exhaust was a single muffler that ran up the side of the cab on the pass. sidehttp://i155.photobucket.com/albums/s...uarterview.jpg. It was very, very loud, so I moved it to here.http://i155.photobucket.com/albums/s.../genset018.jpg



The genset is in a box from Zamzow, I insulated it and placed this genset inside the box. The exhaust system is insulated and the large fan in the left side of the box takes the hot air out of the box and keeps it at 145 degrees.http://i155.photobucket.com/albums/s.../genset036.jpg

The electrical components are all easy to get to, as well as the coolant pump and the belt tension pulley.http://i155.photobucket.com/albums/s.../genset035.jpg

This is the complete unit. I have finally been able to use it for an entire day. I'll be testing it again tomorrow, but as of now it is working better than it ever has.http://i155.photobucket.com/albums/s.../genset034.jpg

This is the muffler, it's all the way in the back,I looped a resonater and a muffler, welded them together and it is very quiet, but still has great flow.http://i155.photobucket.com/albums/s.../genset026.jpg

The tailpipe runs up inside the frame , under the fifthwheel and out. The intake runs up under the hood of the truck.

These are the six deep cycle batteries that are kept charged by the solar during the day, the truck engine while I drive, and the genset.http://i155.photobucket.com/albums/s.../genset033.jpg

Your setup is no good. There are no wire nuts.

or a wad of electrical tape.
or a............ FIRE!!!!!!!!!!

What are the dimensions on that setup?

The box is 48"long 24"by24" square.
The genset is 27"long 14"deep 16"high and weighs about 200lbs.

Is there any particular reason the box is almost twice as big as the generator?

In case of repairs, I like to be able to get in and not be cramped. It also leaves room to get a bigger better unit. When I got the A-Trans unit it was inside a box that left no room for even adjusting the belt. It was a very poorly designed system. Thats probably why they went out of business so fast.

How much do you figure your whole system weighs? I've put together a couple of "apu's" , i started with a used 2 cyl engine from a stright truck reefer......

I figure the system weighs about 350lbs that box and all.

I ran the unit today for a test and after 4 hrs the capacitor (the little black box at the bottom) started to melt a little. So I relocated it to the outside where the ambient temp was 40 degrees lower than the inside of the genbox, and all was well. I got the inside of the sleeper down to less than 63 and it was 102 outside.

http://i155.photobucket.com/albums/s.../genset035.jpg