Although this project is not completed as of yet, I thought I'd share how I'm going about it and where the project is at today.
I realized right away that a few things would have to be addressed. First, due to the tight spaces in the F-26 this enclosure would have to be removable without tools for quick and easy access to the pumps, rudder gear and stuffing box behind/under the enclosure in the event of an emergency. Secondly, it has to allow for adequate ventilation to get the heat out. Thirdly, if this thing is going to be a part of my boat it has to look good. Below is a picture of the area that I have to work in.
I started the project with a tape measure and some sheets of cardboard. I made a four sided box with a separate lid. Covering the entire generator took up too much room and really restricted access to the pumps and rudder so I made it narrower. This cleared an access path for me and also took care of the ventilation problem. The back where the exhaust manifold and breather are is wide open as well as the bottom of the enclosure. The next trick was to try to get this thing out thru the generator hatch. To Do this I had to make the enclosure a three piece assembly.
Once satisfied with the cardboard model, I made drawings and sent them into a local fab shop and had them water jet cut, bend and weld the pieces as required. The material is 1/8" 6061 aluminum sheet. Below are some pictures.
The tabs used to join the pieces together are made from the same material as the enclosure panels themselves. The receiver is made three pieces, two spacers and a bridge. The male tab is a single piece sanded a little thinner to provide an easy slip fit. Edges that meet are capped with rubber edging ti prevent rattling.
Buckles are used to hold it all together. The first piece to go into the boat was the forward & port walls. This piece is screwed directly to the fuel tank cradle and is not intended to be removed without tools. This is what supports the other pieces.
Clearance between the enclosure and the breather was minimal and needs to be increased. Instead of cutting greater clearance in the panel which would make this area even narrower and weaker than it already is, I needed to find another option. I remembered that I had a parts generator at home that still had its breather cap on it. I decided that I would take this one and cut out a clearance notch into it, weld a plate into it on an angle to fill the hole and then paint it so that it looks good. (yes, body work Jeff) Below is a picture of the breather marked for cutting. Although it looks nasty now, it wont when I'm done. The entire generator looked like this before restoration.
This next pictures show the enclosure assembled with the rear deck off.
This last picture shows the enclosure in place with the rear deck also in place. Unsnap the buckles and the lid and removable side section come out thru the hatch opening easily.
Well that's about it for now. I've removed the enclosure from the boat and plan on getting it to the powder coater's shop sometime this week for a nice white finish. When I get it back I will be lining it with fire retardant sound proofong before re-installing it. I'm hoping to do the breather within the next few weeks.
I'll post some more pictures of the job when complete. Unfortunately I won't know the results of my efforts until next spring when she goes back in the water but I'm keeping my fingers crossed for good results. And for those of you wondering, I have about $300 into the job not including the powder coat which is really not that bad.
