I've been working on the generator again. I wasn't happy with the control box, wanted to add a fuel level gauge and a digital tach like the one I put on my BX. So I bought a larger box, put hinges on the cover and drilled holes for all the gauges, indicator lights and switches. I also mounted 8 and 10 pole stud type terminal strips and mounts for 2 plug in relays. I made a copper bus bar that connected 4 sterminals on the 8 stud strip for a common ground point. I found a plug in automotive type relay that has a 10 second delay circuit built in to control the glow plugs at start. I has a low current rating on the NC (normally closed) contact, so I had to use it to power a higher rated relay to send current to the glow plugs. I spent a few afternoons getting it all wired up and adding two additional cables to carry all the additional circuits for everything. So now I have a 7 conductor, 4 conductor and two 2 conductor cables going to the engine, with one unused wire on the 7 conductor cable.
I also decided to add an actuator to pull the throttle open instead of just holding it wide open from start to stop, like most gas generators do. I had bought a small one a while back, but it wasn't near heavy duty enough to hold up to the vibration, and it had barely enough pull to open the throttle all the way. So, I looked around and found another one with aluminum housings and able to develop 160# of pull, plenty for the job. It has a 2" stroke, and I only need 1" travel on the shutoff lever, so I came up with a spring loaded clevis that lets the actuator extend and retract fully (it has internal end stop switches) but move the shutoff lever the correct amount. Making the mount for it was a two afternoon job, and looks kind of Rube Goldberg, but will do the job. I added a DPDT switch to the new control box with an idle and run position, so it can be started and warmed up, then move the switch to run, and it runs at the full 3600 rpm.
As I mentioned before, I'm going to have to come up with some sort of intake silencer on this thing. The intake drone from the little 3 cylinder Yanmar is really loud even with the air filter in place. My sound meter shows over 100db from 3 feet away. I don't understand why it is so much louder than the 3 cylinder in the BX. I wonder if I could come up with a 3d printed Tesla valve that would work. Hmmm.
I was going to remove everything from the mounting cage and have it powder coated, but I think I may end up partially disassembling it and masking off everything I can and paint it instead. We'll see how ambitious I am.