Hi Bob,
As you have been good enough to have so much input, I thought you might like to see the finished product.

My worrying brain had already decided to re-route the plastic fuel line and I managed to get hold of some small bore hose as sleeving. As you csn see I made an add'l bracket to tie the line up to.

The new fuel tank looks pretty good - you can see that it is undersize for the G400 and does not span both the engine brackets which would normally hold it. However my bracket attached to the engine cover plate looks ok and there is minimal vibration. The new tank holds just under a gallon so I am happy with that.

You can see that my muffler problem was fitting it between the air filter and the throttle linkage, still ensuring it was adequately fixed so it wouldn't rattle itself to bits. As I have no welder, I gave in and went to 'Macs mufflers'. They used my old exhaust flange and made up/welded a new muffler (fibreglass wrapped) and brackets. It cost $150 including some repair welding to frame. I think they have done a smart job but its blown the budget a bit. If anyone in Brisbane North would like to be hired to give me mig welding lessons I will jump to it.

The finished article starts first pull, has plenty of compression, runs smoothly with no smoke. I have set the throttle so the generator pushes out a constant 240volt. The whole job owes me about $400 which is pretty good for a 5kva Dunlite generator - I think!?

Many thanks again Bob.[Linked Image]
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