Honda 2000i Generator Exhaust Extension

During heavy storms when the power goes out, I wanted a way to keep the generator running inside a garage (with the door open about a foot and yes I have a carbon monoxide detector in the garage and in the house) or in a tool shed so not to have the generator running unprotected outside getting wet during rain/snow from the storm when the generator power is most likely needed. I didn’t want a complicated permanently attached exhaust pipe. I wanted to maintain the generators portability because I use it for power tools including my new WORX electric chainsaw.

This is what I came up with, a simple exhaust extension using simple hand tools, hardware store pipe components and a little help of a welder friend.

Materials used in exploded view:

• 5 feet of 1¼in ID Flexible Stainless Steel Exhaust pipe. (What's not shown is a 12-foot long exhaust pipe that couples to the flex pipe to get the exhaust even further from the garage).
•  http://www.summitracing.com/parts/wlk-40001
• ¾ in npt x 4 in nipple
• ¾ in npt pipe coupler.
• ¾ in npt x 2 in long pipe nipple.

Assembled components. I’m waiting for my mail ordered 1¼ dia muffler clamp to secure the flex pipe to the nipple.

Generator before exhaust modification.

Rear grill removed showing the muffler.

Holding the short nipple onto exhaust port to show you how/where the short nipple will be welded on.

Muffler removed, just three bolts.

Close up of the muffler exhaust port.

Close up of exhaust port with nipple ready to be welded onto the exhaust port. 
In the photo it appears I cut off some of the threads of the nipple. I didn't, what I did do was grind the threads on one end so the nipple metal was thinned down to about 1/32 inch thick. This was so the sheet metal of the muffler and the end of the nipple were about the same thickness. This lesson the chance of too much welder amps needed to melt the nipple and not burn holes in the muffler steel.

New welded exhaust nipple through grill.

The flex pipe adapter nipple and coupler that thread onto the welded nipple.

Flex pipe installed.

Flex pipe installed and on the ground. 5 feet of flex pipe used. ( not shown is another 12-foot long exhaust pipe)