Honda EU3000i Weather Proof Cover

Dec 27, 2002 Fri0Generator

The finished cover with the end pieces installed.

I recently purchased a Honda EU3000i generator. During summer travel I run a generator all day to power the air conditioner in my Wildcat so restroom breaks and lunch can be enjoyed in comfort and also to power a crock pot for the evening meal.

I travel about every other weekend during the summer and plan to leave the Honda in the truck bed most of the summer. I wanted some way to protect it from the rain and sun, and also to hide it from curious eyes while parked at Wal-Mart.

My Dad and I made the following cover in about a day and a half. About half of that time was figuring out to how to do certain things. We could build another one now in less than a day.

Both ends are easily removable while the generator is running. The top and sides are one piece of aluminum and remain attached while the generator is running. This piece will only be removed when the generator is removed from the truck or I need access into the inside of the generator.

There is an access door on the top to permit refueling and a window to view the fuel level indicator.

The metal is diamond plate aluminum, I think 0.060' thickness, and cost $112.00 for a 4x8 sheet. I have about a third or more of the sheet left for a future project. I had the sheet metal place make all the cuts and bends and the total cost for the metal and labor was $144.00. I probably have $30.00 to $40.00 in angle aluminum and bolts.

My Dad came up with the method of attaching the end pieces which uses a broom handle clip that snaps onto the Honda grab handle and works very well.

The base is pressure treated wood. There are wooden blocks on all sides of the base of the Honda so it can not slide around on the wooden base.

Close up view showing the end piece inside the main cover about 3/4'.

End piece removed showing the aluminum angle strip making a 'stop' for the end piece. The two short 45 degree strips of metal stiffen the main cover.

Close up showing the 45 degree strips. I used stove bolts and counter sunk the heads for a smooth flush fit.

I used wood to hold the bottom of the end pieces close to the 'stop'. To insert the end pieces, I place the bottom first behind the wooden block and then snap the top into place.

The main cover is attached to the wooden base with four 5/16' studs pre drilled with holes for spring pins. A washer and spring provides a constant pressure but are easy to remove when I want to remove the main cover.

These are broom handle holders and are mounted on the back of each end piece. These snap onto the grab handles of the Honda EU3000i and hold the end pieces in place.

The exhaust side with the end piece removed. I kept the cover close to the Honda on all sides to reduce the total size. Note there is a gap in the wood strip on the base which holds the Honda in place. This allows a small container to be placed under the oil drain so I can change the oil while the Honda is in the cover.

It is difficult to see but there is a door on the top that can be removed to access the gas cap on the Honda. The black rectangle is a piece of clear plexiglass that permits me to view the gas level indicator on the Honda.

The gas cap access door removed. I used two cabinet magnetic latches to hold the door in place. There are two dowel pins on the back two corners to aid in placing the door correctly. I framed the hole with the angle aluminum and put clear silicone under the strips. There is weatherstrip on the door. The angle aluminum provides a smooth sealing surface.

Close up showing the access door with dowel pins and metal plates that line up with the magnetic cabinet latches.

Close up of the framed gas cap access hole. The size of the hole is 6' square.The angle aluminum is attached with counter sunk stove bolts.

The Honda sitting on it's wooden base with the cover removed.

Cover in the truck with end pieces attached and the Honda EU3000i inside out of the weather. Notice the strap steel with bolt that sticks into a hole in the hitch rails. There is one on both sides. This prevents the whole thing from moving in the bed.