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I'm building a replacement for the actual speed controller itself. Unfortunately my contract on the west coast has been extended so I won't be home to finish the project up till the fall of the year. It will be one of my priorities when I wrap up this project. That amount of pull-off is what...

Keep an eye on that controller. What you are describing with the thing freaking out after a while is the beginning symptoms of controller failure. Glad you have the magnet setup working better. What is the pull-off force right now?

I have used voltage and frequency to set one up. Use the one you have the gear to measure. You will be fine. Frequency will be a tad more accurate but not so much so to make a difference in operation.

Yep. The magnet is too strong. Get it down to 4.5 lbs and see if it will pull off. Its a compromise between weak enough to pull off but strong enough to hold it for shutdown.

Try this for troubleshooting. Before you try to start the unit unstick the magnet from the target. Turn the unit to run on the switch. See if you see the arm on the actuator jump. On all mine the target pulls away from the magnet as soon as you turn the unit on.

You don't need big CCA batteries for these generators. Especially in Florida. When I'm testing sets I use a set of lawn mower batteries. They have about 220 CCA and spin the unit over perfectly well. The batts in my 803 are Optima Red top group 51s.

I've tried to put a group 24 in a 803 because I already had some laying around. I gave up after seeing how close the terminals were going to be to stuff I didn't want them to touch. It will not be easy to get them in there. I've tried. Buy group 51 batteries and use the time you save not...

Very nice setup.

Under no load conditions expect a 802 to use about 0.15 to 0.2 g/hr. An 803 will use double that.

You are not going to ruin the set by running it lightly loaded for a couple of days during an outage. You will collect some junk in the exhaust but its not going to be instant death. You don't have to run it balls out all the time to keep it tidy. You just have to run it long enough with...

NiChrome wire will gain about 15% in resistance going from room temperature to 500C. So under normal conditions your two elements in parallel would drop from 10,800w to about 9100w. Add the voltage drop of your loaded set (230v vs 240v) and you'll drop a little more power. Down to ~8747w. If...

I put together something very similar. Mine was just a little bigger since I use it for various equipment around the shop. Works great for 802s or 803s. Makes moving them around while working on them a breeze.

You can pick up the thermal fuses really cheap at an appliance repair store (online). I ordered them for like $10/ea. Cheap, cheap insurance. Edit - A quick search on Amazon revealed a 2-pack for like $10.

They are the same on the 5kw and 10kw machines. Only the number of turns of load wiring you wind through them is different.

Some of the typical values for 240v elements are 2500w, 3500, 4500, 5500. You can get 1500w 120v elements and put 2 in series. They run between $8 and about $20 each. So for 6500w you can use a pair of 1500w elements in series paralleled with a couple 2500w elements. To be able to create...

Space heaters are a good choice. Simple and effective. You will need to build up an outlet setup that can handle the current. Build a good setup. You'll be using it to keep the set maintained over time. I personally use water heater elements in a bucket of water. Be be sure the set is...

Don't buy it or commit to a price till you've seen a proper load test. Edit - it should be able to do 6.5kw resistive. The engine parts on these things are pricy. You can easily be into $2,500 to go through the engine. Unless they are asking like $500 it could bite you.

+1 with Guyfang. Check with your local rubber and gasket supply company. You can get sheets of material suitable for about any situatation you can think of. Along with some simple punches and chisels you can easily (and cost effectively) make your own.

We got mostly snow in Hillsboro OR. The drivers here are crazy. Amazed how how poorly they seemed to do with some frozen stuff on the ground.

The batteries that seem to fit best are Group 51. Edit - I can report that Group 24 batteries do not fit and are the same basic dimensions of Group 34.