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Old Generator, high CO numbers, stinky!!
Well, boy things have changed, I installed a generator in a recently purchased Jayco F36Z, toy hauler 5th wheel, the issue is, the generator is an Onan Emerald, flathead air-cooled. Not a terribly clean burning engine, reasonable but not delightfully so. I don't mind a little exhaust smell but yeah, it travels and will get inside with the windows open. I took a stab at something, a test. I welded up a new muffler mount, 2 bolt flange, 90 degree turn into a very small, 8" catalytic converter. Then another turn to go back into the factory Onan muffler. Ho boy I recall the era of coring out and removing catalytic converters, I do! Blasphemy now!
I'll add some pictures in a bit if its easy enough to do, but I started the generator, gave it a 3 minute warm up, then added in the AC to get a bit of a load going. The inbound exhaust temperature climbed to 325F and after a bit the outbound exhaust temps were hovering around 435 and the CO rich exhaust smell was gone.
As to the state of tune, the generator has unknown hours, has a new carb plugs and points. all timing and mixtures are set right where they should be and the plugs look dandy. I tried running it a tad more lean but that mostly increased the cylinder head temperatures without a change in the output.
My next mods to the generator are to put some sound deadening material inside the covers, this will help calm the echo from the tin air covers and also hopefully help with the airflow around the engine, I will be running the exhaust out the non-porch side eventually and will be removing the exhaust manifolds for a sandblast and paint before wrapping them in the heat resistant tape. The exhaust under the floor will also have a heat sheild above it, for added security.
-J
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