I live in New Jersey and as I write this instructable on October 28, 2012, we are about to be pounded by hurricane Sandy, To keep my sump pumps going, I decided to buy a portable generator in case the power goes out. The only generator I could get my hands on is this behemoth 225 lbs Generac 5500 watts generator. Keep in mind that I cannot run this generator in a covered open area. First on all, other than my small covered porch I do not have any other covered open area, secondly with 100 miles an hour wind, there is no such thing as covered and open. I had to make a cover which will protect the generator from rain and I will need to provide ample opening for it to breathe and dump its exhaust.
Step 1: The design
As I mentioned before, the generator needs to be protected from the rain. It should be able to breathe. The cover should be beefy enough to stay on the generator. If I was a sheet metal guy like the Tuttles from The American Chopper, I would have done every thing in sheet metal with a cool paint job. Unfortunately my skills are limited to some crude carpentry, so I decided to make a plywood housing with louvered vents for air circulation. I did think of generator getting hot and found the hottest part to be the exhaust muffler. I decide to put a aluminum sheet as a shield against the heat.
Step 2: Start with the top
I used a 24" X 32" X 0.5" plywood as the top. Rest of the structure of the housing would be attached to the top. I still had some nice hardwood railing bars left from the deck I built. I attached those bars to the plywood using 1" long deck screws. In the picture below you see two sides already attached.