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Not sure the epoxy would hold well. Some people install Pop Nuts in those spots so they don't have to deal with getting a wrench into the tough spots.

I suppose you could. One normally wouldn't ever have to replace CR1. If you don't find the short then you may want to do this. The potential short that took out the original diode may reappear in the future and find yourself needing to replace CR1 again. Seems a bit odd the design uses a 3 amp...

1 & 2. You ought to be able to do the repair with the panel in the genset. Just a bit difficult to access it via the drop down panel opening. Might be easier to remove the top cover for better access to it. CR1 is soldered to the standoffs. Instead of soldering a new on in right away you...