Step 3: Mounting Bracket
The generator is small enough to fit in the back of the Geo Metro. However, it is designed to hang down between mounting rails in an RV. The flywheel, oil filter, and muffler all are suspended BELOW the bottom of the generator. You can NOT simply set this generator flat on its bottom. It needs to hang.
So, what I needed was a way to mount the generator in the car AND have space below.
The spare tire well is perfect for the lower space required. Now, I just needed a way to span the back of the trunk, so the generator could hang down into the "below the trunk" area.
Looking through my recycling/scrap pile, I found that I had some pieces of old bed frame. It's a very sturdy material. It cuts well with an angle grinder with a cut-off wheel, and it welds OK. It is pretty difficult to drill a hole in though. You will want some high-quality metal-cutting drill bits.
I test-fit the generator to see exactly where it would go in the back. I also measured the depth of the generator and made sure it would clear the sloping "shoulder" of the spare tire well.
The bracket is a capital H shape. I measured the distance across the back of the trunk, and cut two angle irons that size. Then I cut two cross pieces the length of the generator (16 inches) to go between the cross rails.
After double-checking the measurements, I checked for squareness, and then welded the four pieces together.
I then fit the generator into the bracket, between two sawhorses, so I could see how it would hang, and check for any other issues. Good thing I did! The bottom of the generator has an odd shape to it. I had to use the angle grinder to trim just a tiny bit off one part of the bracket for clearance.
I could then mark the center of the mounting flange holes - two on either side of the generator. I pulled the generator out of the bracket and drilled the holes. First, start with a small drill bit, then work your way up to larger sizes, the last one being 3/8th inch.
The bracket also got 3/8th" holes at it's ends where it will bolt into the car.
Once all the holes were drilled, the bracket got a coat of primer and a coat of black paint.
Then, the bracket goes in the car, and gets bolted in. The generator drops right into it and is also bolted in with 3/8ths" bolts, washers, lock washers, and nuts.