Making a Briggaru Powerstorm - Combining Two Broken Generators to Make One Good

Picked up a Powermate powered by a Subaru EX30 engine. The stator is bad. But that is ok because I have a Briggs and Stratton Storm Responder generator with a bad engine and a good stator. Will combine the Subaru Powermate with the Briggs and Stratton Storm Responder to make a Briggaru Powerstorm.
This is s second attempt at repowering this generator. View the first here: • Storm Responder Genera...
Powermate Generator# PM0435001
Subaru Engine# EX300D520116960
Briggs Generator# 030430-01
I use Harbor Freight Super Heavy Duty Degreaser in my ultrasonic cleaner www.harborfreight.com/1-gallo...
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#GeneratorRepair #SmallEngineRepair #SmallEngine #DIY #Fixed #Troubleshooting #HowTo

[@wotknot1757]

At 3:30 in the morning there's only 1 thing better than watching 1 of your videos. However at age 65 most of the early morning romps are over with, as is working on things while on the floor. Get a lift table son, your back will thank you for it later in life. Another great video, James. Thanks

[@aterack833]

And knees, I’m 27 but ignored all the back and knee stuff, now if I work leaning over something, I have to walk with my knees bent just to see in front of me for the day

[@earlhouse4458]

I started watching your channel recently and I am impressed with your explanation of everything you are doing! You explain so well and why! Keep up the excellent work!!!

[@RetiredPilot]

such a treat to not be interrupted every five minutes with commercials. cheers

[@mcg6762]

Quality work! Impressive how you make sure your builds are ready for really long service without issues. The attention to detail when dealing with the heat shielding issues on this machine was awesome!

[@Woodwhore]

I always learn something new when watching your videos and your calm, concise manner of troubleshooting is an easy way to spend some time learning generators. Thanks

[@giggiddy]

Been turning wrenches for years. But I have found many of your tricks of the trade very useful and time savers. As always, much appreciate your videos and detailed approach.

[@PNWSmallEngineandLawn]

The amount of care and precision you executive is astounding. Very nice.

[@v-g-z3689]

Yeah, thank god there are people around like James, this should be the standard.

[@malcytull]

A true crafts man that has pride in his work !!

[@johncourtneidge]

@@v-g-z3689 yes!

[@derekwflett]

Another great video James. After following you for a few months I have decided to start filming and posting my own repairs. Learning something new every week.

[@butler386]

Congratulations on a job very well done. You are one of the few I see using a breaker bar to loosen a bolt or nut. You did a lot of fixing and got a good heat shield so hopefully the overheating of the stator will not happen again. Great job. Thanks for the video.

[@PeterLawton]

I love the magic of the impact wrench/driver.

[@georgetucker336]

Thanks for the way to transfer engine and stator generator power head. assembly. You make the job look easy. I will find out when I need to do the same. When you know how to mix and match parts is a plus.

[@hamop3]

Another Awesome Video James, thanks for taking us along. Great Job.

[@jcondon1]

Thanks 👍

[@oldsranch]

As usual, another great video from the Generator Whisperer!

[@falloutguy8878]

Very interesting James loving how you talk your way through and show us what you find and great engine swap nice idea take care James

[@FB-tq5ln]

We learn every day, thank you for your video's. Greetings from Dublin Ireland bless you.

[@mcarroll598]

Great video James, the “Hybrid of Generators!” I Really enjoy your videos. I am a journeyman electrician and been working on small engines since I was a young kid. This past week I was using a torque wrench on all my terminations inside the equipment I was hooking up. The start-up rep from the company was so impressed when he saw me with a torque wrench, he said he’s never seen guys use a torque wrench! Lol!

[@jcondon1]

That is awesome!

[@black1985vette]

Just finished two Briggs and Stratton units. Thanks for the insight to the heat shield. I didn't have a spare from another unit so I drilled out the pop rivet nearest the alternator then bent the shield away from the alternator to create some extra gap. I put in another pop rivet and then added a piece to extend the shield down and to the rear just enough to block the stator and fill in the slanted bottom bit. The extension was just light sheet metal bent and then pop riveted in place. These two generator repairs were possible because of watching your videos and seeing how things come apart and go back together. Not sure I would have just figured it out by trial and error without destroying something. Thanks.

[@larrykelly2838]

Doc, that engine sounds great. Your right that combination is a good one.

[@thomasbardwell4151]

If I tol you once I will say it again…sir your very smart… the way you figure out problems is amazing!!!

[@YukonHawk1]

Once again an outstanding fix and finish. Love the modifications you made to make everything fit just right. Alot of hard work will pay off.

[@josephwestin8996]

i guess im randomly asking but does anybody know of a tool to get back into an instagram account? I was dumb forgot my password. I would love any help you can give me!

[@alfonsobaker948]

@Joseph Westin Instablaster ;)

[@josephwestin8996]

@Alfonso Baker i really appreciate your reply. I got to the site on google and Im in the hacking process now. Looks like it's gonna take a while so I will get back to you later with my results.

[@josephwestin8996]

@Alfonso Baker it worked and I finally got access to my account again. I'm so happy! Thanks so much, you saved my account :D

[@alfonsobaker948]

@Joseph Westin you are welcome :)

[@shawnmrfixitlee6478]

Great job James , You made a good machine there ! ENJOYED

[@mjg263]

Great job, a lot of work but well worth it!

[@jeffreyk5933]

Love your videos, I think it's great that you are so contentious about what you do. I just wanted to say that I have removed countless rotors by simply removing the centre bolt and striking the side where there are no windings with a length of 2x6. It comes off the taper every time. It's so easy and fast I am surprised that you don't do that.

[@jcondon1]

Had tried that before and beat the thing senseless and did not come off. Of coarse it was the first one I tried to remove. Have learned a lot since then.

[@johnables6069]

Nice job man. Always quality content

[@kerrygleeson4409]

Always interesting James thanks 🇦🇺👍

[@ronkurey8840]

Excellent video...very educational....thank you

[@woolval52]

As usual, I'm impressed by your work. Not only do you repair these, but you also re-engineer it too! The heat shield improvements are clever. Obviously, your experience helps you see weak design flaws from the manufacturers. They should send you new generators to preview for them! LOL, Powermate sends you a generator and asks "WWJD?". Watching your work always has a calming effect on me, thank you. And I do believe it's helping me be calmer when I work on small engines; I have more patience now. I still love the torque wrench use. You don't see that much anymore.

[@jcondon1]

I only film a couple hours at a time, otherwise I would probably throw something across the room. Would love to preview and review new generators. Maybe someday someone at one of these manufacturers will think the same.

[@petersack5074]

@@jcondon1 yes, especially GENERAC....they need some smartening up, in the engineering department, when it comes to COLD WEATHER OPERATION....cummins or nothing, i guess.

[@andrewgrace4410]

Great work James and fine genny😊

[@fullraph]

Good job, sound like a fun project! Id like to get into fixing and flipping small engines too.

[@westonedwards4353]

Thanks for another great video.

[@xcalibre222]

Man that's back breaking work bending over that thing. You should add a small ceiling hoist from HF to lift this up and set on a small table with wheels so you don't have to bend over. :) Thanks for the Vids!

[@AntonioClaudioMichael]

Great rebuild and recap on the orginal video and build

[@jcondon1]

Thanks

[@rosk3165]

love your videos always interesting

[@Bulletman426]

Great work as always! If the exhaust is that close, you could use exhaust wrap to cut the heat off!

[@philoso377]

Saw your hydraulic and brute technique. It’s educational and entertaining :) You know, we can use pneumatic technique. Pneumatic? When you have a chance get hold of a used nail gun. Use only blank but nail and shoot exhaust into the bolt cavity. Let me know what you think? Caveat? In this case we only have push force but push and pull. Can be compromised with pneumatic leak at the mussel and rotor shaft junction, a rubber washer may help. The best effect is to extend the mussel into the rotor shaft and in front of the motor shaft tip. Few drops of WD40 at the taper junction also help. Last but least - to protect crank shaft: pretension the rotor shaft outwards to provide axial displacement on crank shaft at the moment of separation.

[@zrkn1]

I sure do appreciate you filming your processes. Thank You! It's a shame that Subaru designed such a poor muffler when all they had to do was change the angle and length of the header pipe.

[@jcondon1]

In a lot of cases, the engine manufacturer does not make the muffler. A lot of time the muffler part is shown on the generator parts diagram and not the engine parts diagram. You would think that would have kicked it out at least another inch.

[@deangentles4966]

hi james you put a lot of time in on this one but with a good combine of parts you got a great gene out it good job mate

[@chrismoore9997]

I need a mechanic like you to work on my power equipment. Great job.

[@jcondon1]

Thanks 👍

[@NitroGuyJH]

Briggaru Powerstorn is legitimately a bad to the bone name for a gen-set 🤘🏻Awesome video s always brother, love the kinda work you do!

[@ronaldclark2624]

Like your videos! You seem to be well informed concerning motor generators! The open wires looked more like overload but could be caused by grounding due to loss of insulation but that should be form-bar covering which is Hi-temp if memory is still working correctly. The short was probably at the break with the two wires shorting. Back in the day they would redip motor windings even if they were burned and call it rebuilt. They also used grooving irons in worn out tire treads and sold them as used tires. The windings can be repaired and redipped or even shellacked and they would work fine with heat shield installed! But, time and objective each being a factor? Just Ron

[@annierenard5954]

very good, thank you

[@ericvaughn1126]

I'm a day late on this one, but it now seems "JC Customs" would be a fitting name now that you are doing sheet metal work too! 😉 Meticulous attention to detail as usual. ESPECIALLY ensuring that the same engine didn't get a chance to ruin another stator! Good stuff and keep em coming. 👍

[@jcondon1]

Thanks Eric. Will be starting work on the PowerBack soon...

[@ericvaughn1126]

@@jcondon1 Oh cool. I'm surprised that you have it already.

[@jcondon1]

@@ericvaughn1126 you and me both. Should have it in a couple days.

[@AntonioClaudioMichael]

Sweet you got the power head off water no go oil no go BFH works

[@papabits5721]

Good content as always.

[@tiredoldmechanic1791]

I've always painted exhaust parts on racing cars with high temperature silver or white paint because it reflects the heat so more of it stays in the exhaust instead of radiating to the surrounding parts.

[@Cotton088]

Thanks for the video. I learned a lot. One criticism… I can’t endorse WD-40 as a cutting oil.

[@Yoldark34]

I would have bend the exhaust shield and screw it to the metal frame (the first grey one). Nice vid, thanks.

[@AntonioClaudioMichael]

You can also get the allen head bolts at home depot in the lengthyou need even tractor supply has them bolts also @34:28

[@jantsbenzproaudio2953]

Briggaru got me lol. But hey this is a very good and informative video....

[@raymondj8768]

BRAVO MY DUDE !!! :)

[@jimh375]

Grease would likely work to remove the rotor. Hammering on the side of the rotor could cause excessive runout and a rotor/stator rub.

[@jacobtejchma4708]

This might not be the same thing, but for removing a golf kart clutch I found bread to work the best. It sounds weird but it worked the best for me.

[@ericvaughn1126]

True, but he wasn't ever going to use that rotor again so he was concerned about damage in this case.

[@somerandomguy3868]

Great job James, maybe look into a sticker or even a stencil " Franklin-Condon " or " Condon-Franklin " if you prefer

[@trevs9316]

not sure how i feel about the wood but good video thanks keep em coming

[@jcondon1]

I feel the same way. Wish I had something better for that.

[@marcello_D]

James, excellent videos! To avoid this exhaust heat issue with the stator, do they make a heat shield we can install to protect it? If so, which one? Thanks!

[@AntonioClaudioMichael]

That exhaust on the suburu also looks like a briggs and stratton exhaust not just the spark arrestor plate @James Condon

[@amphibiousone7972]

@jcondon1 this rotor removal reminded ne to recommend (Cheap Toilet Paper and Water mixture) instead of just water in cases like this.. Tganks Again Boss 🤝

[@TopCat2021]

Great video, I came over from Elemental Maker (also subbed) if you want a good plastic instead of wood, cutting boards are the cheapest source of UHMW that I've found and it has many uses.

[@jcondon1]

Thanks, Will check it out. Have recently improved the spacer design, video forthcoming soon.

[@AntonioClaudioMichael]

That power head just don't want to come off does it wow lol

[@henrikjorgensen1614]

Instead of using water to remove things you can drill a channel in the teflontaped bolt and fit in a greasecoupling in the bolthead and use the pressure in a greasegun to free things up If it is a big cavity to fill vith grease can you fill with water mount the bolt and use the greasegun as it is as a pressureraiser The pressure in a grease gun is 300 to 400 bar( 6000 psi ) ,a bit higher than the water pressure and it works well ;-)

[@Peter27076]

Looking at that open circuited stator you could at a pinch go all Mustie1 or AvE and carefully free up the broken wires, solder in a small link to connect them up again then thoroughly insulate everything then put the coil back in service if it then tests OK. This is of course assuming that there are no other short or open circuit faults in the coils and that the previous heat soaking will not cause another failure in the future. I would also modify this generator and others of the same configuration with the muffler unshielded and close to the stator by adding a sheet metal heat shield between the muffler and the stator.

[@Farm_fab]

Jim, if there's a plastics distributor in your area, you might check their throw away stuff to see what is useful to you. I would look for black stuff to make it look better. If need be, I could send you something that is useable to you. Also, FYI, TPI means threads per inch.

[@johncourtneidge]

Again, well done and thank-you. I wonder if there are any exhast mufflers that crank outwzrds to give more didtance from the stator.

[@donalddrago7728]

It is sad that Subaru stopped making small engines. They were far superior to Briggs and Kohler. They did not do a good job of marketing their engines. Now the only really good small engines are Honda’s.

[@AntonioClaudioMichael]

Good video bro

[@deangentles4966]

hi james as always great sitting in your class ,you say you keep finding heating with this exhaust kills the stator then briggs and stratton need to look at this and try putting a thin and longer model exhaust on its models maybe mate

[@Farm_fab]

If you sand even lightly before painting, it won't peel as quickly.

[@tedheierman1181]

You could also treat the muffler with 3M rust converter. Then apply a suitable final coating.

[@richardfote4083]

You need to use a flex socket for the bolts in tight spots.

[@jerrysoutherland662]

Another great video,James.Did you say that engine was a EX30subrau.

[@jcondon1]

Yes it was

[@Jan324td]

Hello James, grettings from Germany. Great job like always but please use some Steel or Aluminium Spacers for the Mountings.

[@jcondon1]

Did that more recently swapping a blown Briggs with a Yamaha. I liked it better, but some commented it will not last. Need to figure out something better.

[@Jan324td]

@@jcondon1 Maybey try some PTFE and glue some Rubber mats like they are used on heave trailers to secure loading .

[@chandlerdavis952]

When all else fails "Get a Bigger Hammer" ! Lol

[@stevewebb5735]

I wonder if those burned wires could be jumpered with extensions maybe using crimping, and if not solder?

[@JohnStenstrom]

So do I.

[@philoso377]

Hey Jim if we label those space heaters with Watt value it will show up in video each time so we don’t need to edit wastage on the screen. What do you think?

[@LunkerFishing]

Great job but before I pulled that carb I would have at least blown off the carb with shop air and/or carb spray to keep all that dirt from entering the intake manifold and falling into the carb. I know you were going to use the ultrasonic but why let all that dirt get into the carb passages anyway and you can see what you are doing much better on a relatively clean carb. Also, that crankcase breather tube is supposed to feed back into the air filter box.

[@davidbalfour3390]

I was wondering when you were just going to hit the stator, you could probably wobble it with your hand to eventually get it off.

[@SteveHacker]

Awesome as always! Two questions: 1) Is this what you do for a living, or is this a side hobby that makes a little money via generator sales? ... and ... 2) Wouldn’t your work be easier with a large bench or lift so you’re not having to work on the ground?

[@jcondon1]

This is a just a hobby to make a little money on the side. I have a bench, but no lift table yet. A lift would be useful.

[@zonie1953]

I wish i lived close to you James ! I have a carb question on a brand new Honda EU2200i .

[@FishFind3000]

Use the warranty

[@philoso377]

A word about heat shield. Black body take in and pass on heat better than shiny body. Black color work best on muffler and shiny body on heat shield. How far do we go out shielding? If ambient max is 100F and enamel soften at 300F we need 200F or less temperature rise above ambient plus a safe margin. That makes it 140F degrees rise. If ambient is 80F and rise limit is 140F then motor case temperature should measure 220F or less. Bare or anodized aluminum sheet can be good material in heat shield. Oxidized aluminum color is white, anodized is silvery. Oxidized iron and steel? Nearly black.

[@mariowilliams1580]

Hi James the exhaust is even closer on this stator - you must do something to change how it fits or it will cause the stator to fail!

[@jcondon1]

The original one was square without a head shield (so all of the stator was an inch close). This one is a half inch closer, but it is round so only part of it is closer and is has a heat shield now. The original configuration lasted 10 years. This one should last longer.

[@luiscruz-no3ib]

Is that CLR you used for carb clean .i watch your videos learn a lot keep going

[@jcondon1]

Harbor Freight super heavy duty degreaser

[@luiscruz-no3ib]

Try CLR it works good on ethanol fuels won't damage plastics or rubber

[@robertfountain4856]

Great job creating that blend of components. I don't like your piece of wood and if you could weld, (I don't know what you have available) how about cutting off the engine cross support of the Storm Responder chassis and re-welding it in a lower position to provide a level assembly. You said you may just do a few more like that ... Just don't rely on the rubber mallet to separate the stator from the engine. There has to be a better way. Make a sketch of that heat shield before you sell that Brigaroo. Yes I agree with Wotknot ... You need a table lift if only to get it to roll onto a work bench.

[@jcondon1]

Just did another one recently and was able to eliminate the block of wood. kzbin.info/www/bejne/rp3WhX2Zf92Hp9k

[@michaeltarasenkoop2389]

I have a great idea if they made the manufacturers of the gen give the generator buyer a several year garen Ty and make them fix the broken unit at there expense they would probably build a more beady unit !or give you half your money back ! Those burnt wires should have a heat shield or better insulation on the wires !

[@walterbordett2023]

What are you using for cleaner concentrate in the ultrasonic cleaner for the carb? I have used dishwasher detergent powder or water based parts cleaner or straight undiluted simple green. All worked. Some blackened the aluminum more than others. Heat helps a lot.

[@jcondon1]

Harbor Freight Super Heavy Duty Degreaser diluted with water.

[@AntonioClaudioMichael]

At the end defenitly sounds like the heat shield is rattling to me but I could be wrong

[@williamwhitehead8362]

What about putting a heat shield in back of the muffler for the new stater that you installed to kind of isolate it from the heat or was that not a thought you were thinking of just a question enjoy your films and videos. I I had to change my oil and I put full synthetic in 10 W 30

[@jcondon1]

I did add a heat shield at the end.

[@sammyg3697]

Is it the stator though or is the muffler on the Subaru hotter?

[@Roy_Tellason]

Why is it okay that the heat shield between the stator and the muffler has holes in it?

[@DavidScheiber]

I just had a thought, maybe the knock was related to the wrist/piston pin? like maybe it was loose in some way?

[@jcondon1]

It is possible. I found one issue with the crank gear that meshes with the cam. The key was worn and the gear not locked very well in place. Will take it apart again and check the pin and crank better.

[@matthijsverweijmeren6114]

@@jcondon1 looking forward to your video on investigating the cause of the knock issue so we can learn from it 👍

[@edkennard72]

James where do you hook up the tachometer to check the speed on a generator I seen you do this before and I've always been curious thank you

[@jcondon1]

The one I have is inductive. I just wrap the tach wire around the spark plug wire and it measures it counts the sparks to determine the rpm.

[@markusedma]

Sure looks like someone had been in there before and repaired the old stator.. that area had some fresh looking winding paint.

[@rambuseighty-eight8874]

Use car header tape for heat shielding. Much superior.

[@jeffreyhaynes5774]

You can repair those burnt stator turns,nothing to loose.

[@jcondon1]

True, but would not want to sell it to someone. I would consider rewinding it, but unfortunately the manufacturers do not seem to publish anything on how to do that.

[@jimvincent6408]

How about trying an autobody dent puller? Tread it in and slide hammer on it.

[@Farm_fab]

Gm and Subaru had worked together for a while when GM owned Saab. One model of that car came with a Subaru engine and it was dubbed a Saabaru.

[@bigguy1526]

Hi James ? Why couldn't the wires be soldered back together and also insulated like any other copper ?

[@jcondon1]

That wire is magnet wire and coated with varnish. Would need more slack to bend the wire out and remove the varnish before it would be possible to solder. Did not see how that could be done with what was left. Plus the wire that was left probably had degraded varnish due to the heat. Would be better to just rewind the stator.

[@heliodorovela9315]

THAT IS NO BIG DEAL FOR MY FRIENDS IN MEXICO THEY CAN REWIND THAT AND MAKE IT NEW

[@jared5862]

I have a GP5500 that I recently repaired only to find out the rotor has since went bad. I also have a Homelite 5000 watt that the motor is bad on. So my question is gave you ever tried to put a powerhead from a Homelite on to a Gp5500?? It appears it will bolt straight up because it looks nearly identical. Another thought I had is I watched some videos on rewrapping a rotor and it looks extremely simple. Have you ever tried that?

[@jcondon1]

If both use a Honda clone engine, then you can probably combine two broken to make one good with some modifications

[@michaelhuey4187]

3 questions: (1) why not just move the powerhead from the Storm Responder onto the Powermate frame? (2) is it possible to fi the broken stator? (3) what can a homeowner do to insulate the stator from the heat of the exhaust to prevent the problem you showed us from happening?

[@jcondon1]

1) The Husky frame is small and probably would not accommodate the larger stator, the frame Powermate frame was labeled 5000 watts, The powermate frame was rusty, wanted to use the briggs heat shield, the storm responder has a larger tank, also the stator wiring harness plugs into a Briggs outlet box. Could be connected to the Powermate, but would have involved cutting and splicing wires. Most of those reasons were not show stoppers except the larger size of the stator. 2) Not possible to fix that stator 3) If its a subaru EX30 engine then the heat shield I ended up using will work on most. Otherwise would advise to not but a generator with the exhaust so close to the stator unless it is shielded. But if you have one, you can always buy some sheet metal and rivets and bend something up.

[@MsDave64]

Would it not have been easier to remove the rust from the muffler if you took it off first?

[@HandFromCoffin]

James, which do you think is better the Brigs or Subaru engines?

[@jcondon1]

The Subaru EX30 on this generator is better.