Generator Exhaust Extension | Why Do You Need It? Kit or DIY

Home Generators are becoming more and more popular because of grid failures, extreme weather conditions or even in emergencies. While standby generators are not economical for everyone, portable generators are the preferred choice due to their relatively low cost, portability and low-maintenance. Most home generators run on diesel, gasoline, natural gas or propane. Irrespective of the type of fuel, every generator produces some sort of exhaust gases, which are an unavoidable by-product of internal combustion engines (as a generator is essentially an internal combustion engine). You can divert these gases using a generator exhaust extension.

There are generator exhaust extension kits readily available in the market or you can make one yourself using simple components. In this guide, we will learn more about generator exhaust extension, what is the need for one and how to make a generator exhaust extension as a DIY project.

Working of a Generator

Before learning what is a generator exhaust extension and its use, let us quickly take a look at the internals of a typical home generator. A Generator is a mechanical device that converts chemical energy stored in the fuel (diesel, gasoline, natural gas, propane) into electrical energy.

The anatomy of a generator is very simple. It consists of an internal combustion engine (usually a four-stroke engine), an alternator (AC Electricity Generator), a fuel tank, starter, battery, radiator, control panel and a few other parts. Working of a generator is also simple.

Supply the fuel and start the engine (most modern generators come with self-starters and if not, you have to manually crank it). Once the engine is up and running, it will spin the alternator, which in turn produces electricity.

Like any other internal combustion engine that we have in our cars, motorcycles, trucks, buses etc., the engine in a generator also works in the same way. It takes the mixture of fuel and air through an intake, combusts the fuel inside the cylinder, produce power to rotate the crankshaft, transfer this rotational energy to spin the alternator.

In this process, the engine of the generator produces harmful exhaust gases during the exhaust stroke of the engine. The main compounds of exhaust gases of most internal combustion engines are nitrogen and carbon dioxide, which is extremely dangerous if you inhale it.

What is a Generator Exhaust Extension?

Placement of your home generator is very important with respect to ease of access, noise and importantly exhaust gases. Most manufacturers do not recommend placing portable generators indoors or closed areas.

While people with garages and sheds are at a benefit as they use some space there to place the generator. But again, we have to be extremely careful and make sure that there is enough air flow in shed/garage so that you can work there without feeling suffocated or to push away harmful exhaust gases.

A simple but very useful solution is to use a generator exhaust extension. But what exactly is a Generator Exhaust Extension? It is a simple set of connectors and tubes that connects to the exhaust of the generator and diverts the exhaust gases away from you.

There are ready made kits available in the market (both online as well as stores) that you use to extend the exhaust pipe of your generator. You can also make one yourself very easily, provided you have the tools and accessories.

Why You Need a Generator Exhaust Extension

Consider this scenario. You are using your generator, which is inside a shed/garage, to power your home/shop and you want to work at the same time. An exhaust extension for your generator comes very handy in this case as you can easily divert the exhaust gases to a different location and you can carry on working without worrying about inhaling harmful fumes.

Even if you are not in the same room as the generator, make sure that the area is properly ventilated as carbon dioxide, which is odorless, cannot be trapped in a closed space. Connecting an extension pipe/tube to the generator’s exhaust will make sure that there are no harmful gases in the surrounding area.

Direct exposure to generator fumes can also cause irritation to the eyes, throat, and lungs. Prolonged inhalation may lead to dizziness, nausea, or more severe respiratory issues.

Using a generator exhaust extension significantly reduces the risk of carbon monoxide poisoning, which remains a leading concern for generator users.

The extension directs exhaust gasses to open spaces, keeping harmful fumes away from enclosed or poorly ventilated areas. By controlling where the exhaust exits, it keeps people and pets safe from toxic exposure.

With an exhaust extension, users will have more flexibility in deciding where to place their generator. An exhaust extension can also help in directing the sound away from sensitive areas.

Generator Exhaust Extension Kits

If you are planning to use an extension for your generator’s exhaust, then there are several kits available online. These kits are compatible with most of the popular generator manufacturers such as Honda, Champion, Westinghouse, DuroMax etc.

Some kits come with just the hardware to extend the exhaust and some kits come with all the things you need including the hose as well as a muffler. These are very easy to install and it saves a lot of time as you can fit them right away.

DIY Generator Exhaust Extension

If you are a maker and are familiar with the tools, you can make a generator exhaust extension by yourself as a DIY project. The process is also very simple: have the right set of tools, take a few and accurate measurements, attaching some parts and et voila, you have created an extension for the generator.

Components Needed for DIY Generator Exhaust Extension

Flexible metal tubing or heat-resistant hoses acts as primary materials for directing exhaust gasses. Stainless steel or aluminum tubing works well due to its durability and resistance to high temperatures. Flexible hoses, on the other hand, are easy to navigate around obstacles or sharp corners.

Pipe Clamps (or Hose Clamps), adapters, and sealants are necessary for securing the extension and preventing leaks. To complete the project, you will need basic tools such as:

• Ruler, Tape Measure
• Vernier Caliper (for accurate measurements)
• Wrenches
• Screwdrivers
• Metal cutters
• Heat gun (to soften flexible hoses)

Take Accurate Measurements

Start by measuring the exhaust port on your generator to determine the correct diameter of the extension tubing. Use a caliper or measuring tape to take measurements. Each manufacturer has their own exhaust size and hence it is usually not a standard value. Make sure that you take the measurements very accurately for the extension to work properly.

Next, decide the desired length of the exhaust extension based on the distance needed to redirect fumes safely. Speaking of extension, you have two options: a pipe or a tube.

With pipe, you don’t have the comfort of bending/flexing it the way you want (unless you have pipe bending tools).

With a metallic tube, you have the luxury of bending, curving it the way you want. It is flexible and as it is made up of metal, it is also durable.

Install the Exhaust Pipe

Begin by cutting the pipe/tube to the required length using appropriate cutters. Smooth the edges with a file to avoid injury or difficulties during attachment.

Before installing anything, properly clean the exhaust of the generator. Position the tubing near the exhaust port to confirm that it aligns properly before proceeding.

If you are using an adapter, attach it to the generator’s exhaust port and use clamps to secure the adapter tightly in place. Fit the tubing onto the adapter. Apply heat-resistant sealant around the joints to block small gaps. Allow the sealant to dry according to the manufacturer’s recommendations before testing the extension.

If you are not using any adapter, you can attach a pipe/tube directly to the generator’s exhaust. Now, you can use either a hose clamp or a pipe clamp to secure the extension to the exhaust. We recommend a pipe clamp as it works with pipe as well as hose.

Loosen the screws of the clamp, slide it onto the exhaust and leave some room to insert the pipe/hose. Now, slide the pipe/hose onto the exhaust (pipe/hose must be slightly bigger than the diameter of the exhaust) and slide back the clamp onto the pipe/hose.

Tighten the clamp using the screws. Wiggle it slightly and make sure that the hose doesn’t come off. You can now route the hose to wherever you need, preferably outside the shed/garage with decent air flow and also it shouldn’t come in your way.

For added stability, use brackets or ties to support the tubing, especially for longer extensions. Position the tubing so it redirects exhaust gasses safely away from people, doors, and windows.

Safety Checks

Once the assembly is complete, inspect all joints and connections carefully for any signs of gaps or loose fittings. Use a flashlight to check hard-to-see areas and confirm that clamps and adapters are tightly secured.

Run the generator in a well-ventilated area and observe the exhaust extension while it operates. Watch for proper fume flow through the tubing and away from the generator. Avoid touching the tubing during operation, as it can become extremely hot.

Perform a leak test by applying soapy water to the connection points while the generator runs. Look for bubbles forming at the joints, which indicate leaks. If you detect leaks, stop the generator and tighten or adjust the connections before retesting.

Generator Exhaust Extension: Kit and DIY Cost Comparison

Ready made generator exhaust extension kits typically cost between $50 and $150, depending on the brand and features. Kits designed for specific generator models often fall at the higher end of this range.

Universal kits, while generally more affordable, might not include adapters that fit all exhaust ports (you have to purchase them separately).

DIY exhaust extensions often cost less upfront, with materials totaling $20 to $50 on average. Flexible metal tubing, the primary component, usually costs around $10 to $20 (depending on length and material). Clamps and adapters typically range between $2 and $10 each (depending on their size and quality).

Heat-resistant sealants add another $5 to $15 to the overall cost. Basic tools like wrenches or screwdrivers are often already available at home, but purchasing additional tools such as metal cutters can increase costs by $10 to $30.

If the generator requires specialized adapters, sourcing them might add unexpected expenses. For example, uncommon exhaust port sizes may necessitate custom fittings, which can cost $10 to $25 per piece. Hidden expenses like these may narrow the savings compared to readymade kits.

Time investment is also completely different between the two. A ready made kit typically takes less than an hour to install, while a DIY project may require several hours of preparation and assembly.

Conclusion

While generators are becoming common now-a-days, using them properly and safely is also important. A Generator Exhaust Extension is a very useful modification you can make to your generator to divert the exhaust fumes away from you. We saw about readily available kits, that you buy and install them instantly or you can DIY with simple parts and tools.