Step 3: Mounting Bracket
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.