7 Steps on How to Build Wheel Kit for a Generator

Regardless of whether you’re an avid adventurer or live miles from a power source, wheel kits can provide countless benefits for your generator.

If you already own one, consider adding wheels to it – you may find that your generator is now more convenient and effective than ever before. Or, if you have yet to purchase a generator, it may be worth investigating generators with add-on wheel kits to maximize your convenience and flexibility.

Either way, wheel kits are easy to build; just a few tools and accessories are needed.

To see how easy it is to turn your bulky machine into something mobile, check out our guide on building a wheel kit for a generator.

What is a Wheel Kit

How to Build Wheel Kit for a GeneratorBefore we delve into how you can build a wheel kit, it’s essential to understand what one is.

A wheel kit is, in short, an accessory for your generator that lets you roll it around. They’re beneficial if you want to set up your generator in an inconvenient location, such as on uneven ground or through rough terrain.

By building your own, you can move your generator without having to pay for installation or hooking up electrical cords every time. What more? It’s easier than it sounds.

DIY Wheel Kit for a Generator

For DIY enthusiasts building their wheel kits could be very interesting. It requires basic skills. There are many options available when creating one, including modifying existing wheels and building an entirely new set.

The following list outlines all steps required:

Tools and Materials Required

  • Four used tires

How to Build Wheel Kit for a Generator

  • Two pieces 3⁄4 inch plywood
  • Threaded rod 
  • Washers
  • Bolts with nuts
  • Metal brackets
  • A drill with drill bits

How to Build Wheel Kit for a Generator

  • Sander

How to Build Wheel Kit for a Generator

  • Paint roller

7 Steps On How To Build A Wheel Kit for a Generator

1. Buy or Modify Existing Wheels

The first step in building a wheel kit for your generator is determining what wheels to use. When choosing the reels, you can decide to either pick off-the-shelf parts or modify something like bike tires to fit on an axle.

If you choose modification, ensure the wheels have enough room between them so that they can connect with the axles without rubbing against each other during rotation.

In our case, we’ve decided to go with a four-wheel kit.

2. Create Spindles Using Drilled Holes

The spindle connects both wheels, moving as one unit, allowing you to steer your setup easily. Create spindles out of steel pipe or threaded rod.

To do so, mark off where you want to drill holes based on your axle and tire measurements. You will want 3-4 inches between centres when drilling holes into a threaded rod and 4-5 inches apart for steel pipe.

After adding several washers nuts between each hole, slide it through and connect both ends with a lock nut. Ensure that all pipes are even before continuing. If they aren’t, then adjust until they are perfectly straight.

3. Trim Hub Caps with Pipe Cutters

Attach all four pieces onto your axles and leave around 1/8 inch play. Next, use pipe cutters to trim back each hub cap about 1/2 inch. This step allows you to give yourself more movement if needed without compromising stability too much.

Carefully apply silicone lubricant to prevent rust from forming during storage or transport. Now that you have created your wheel kit for a generator, all you have left to do is mount it.

4. Create a Frame for Your Generator

This frame serves two purposes: securing and protecting your engine from damage and providing a sturdy platform on which to attach your wheel kit. Depending on what materials you have lying around, you can use either wood or metal to construct one.

5. Mount the Wheel kit to Generator Frame

To attach your wheel kit, use angle iron cutoffs and weld them into place on both sides of your generator frame and each wheel assembly.

After welding them in place, you can now mount each wheel using an axle bolt or a carriage bolt (again with nuts and washers). Ensure each wheel is centered on its axle and can spin freely.

At last, tighten everything together by spinning each wheel while holding it upright and ensuring they are straight and even with one another. And while doing so, ensure you have an even distribution of weight across all the wheels. If one wheel doesn’t have enough weight, it could cause instability.

6. Attach the Handlebars

To make steering easier, attach handlebars onto your axle. You can create them out of steel rod or tubing wide as you want them (typically around 1 1⁄2 inches).

Before fastening the nuts and bolts, ensure no play in either direction when turning on your generator.

7. Test

Test your newly constructed wheel kit by lifting the generator from the ground onto a level surface. There should be no wobbling or rocking motion after competing mounting.

Benefits of a Wheel Kit to a Generator

1. Allows Easy Storage and Transport

How to Build Wheel Kit for a GeneratorA wheel kit is an easy way to move your generator around when needed. These kits are usually pretty lightweight and straightforward, but they make it easier for you to get your generator from place to place without any extra effort on your part.

You can strap it on top of a cart and take it down to storage or bring it out when you need additional power during an emergency.

2. Weight Balance Remain Constant

Without wheels attached to your generator, sometimes uneven ground can cause it to tilt forward or backwards. However, there is no need to worry about keeping proper weight balance with a set of wheels because its weight will always remain completely even.

3. Protect Your Generator from Rusting and Corrosion

One of the significant issues with generators is that they are very exposed and susceptible to rusting or corrosion. With a wheel kit, you can move your generator around more efficiently, which will give it less exposure to moisture and other contaminants in your area. This means it’ll be less likely to rust and corrode.

4. Cost Saving

The initial cost of installing a wheel kit is much less than purchasing an entirely new generator. Since your existing generator continues to be functional, you can continue using it in addition to adding mobility.

Frequently Asked Questions on How to Build Wheel Kit for a Generator

1. What is a wheel kit for a generator?

A wheel kit is a set of extra pieces added to an existing portable generator to make moving it more manageable. Generators are generally heavy, making them difficult to transport.

The wheel kit consists of one or two large wheels and several smaller ones attached directly to your power generator with brackets.

2. Do I need any experience to build a wheel kit?

No, you don’t need any experience at all. As long as you have some essential hand tools, you’ll be able to put them together in no time. We’ve included detailed instructions to build one.

3. Can an incorrectly installed wheel kit cause damage to my generator?

Unfortunately, yes. Incorrectly installed wheel kits will not cause damage to your generator. You must follow installation instructions and ensure that you have correctly tightened all bolts, fasteners, and other components. Inspect your wheel kit after every use.

4. How do I change the wheels on my generator?

To replace your wheels, you’ll need an Allen wrench, a socket wrench set with both metric and standard sockets, and a screwdriver. Remove any existing screws that attach your old wheels to your generator.

Line up each bolt hole on your new wheels on your generator to attach new ones. Insert bolts into these holes and secure them tightly using an Allen wrench.

5. How do you put wheels on a predator 3500 generator?

Predator 3500 generators are one of the most popular gas-powered portable generator models. However, they do not include wheels or heavy-duty handlebars by design. To put wheels on your 3500 generators, follow our guidelines.

6. Who owns Coleman Powermate?

Coleman Powermate, founded in 1900 by William Coffin Coleman, is an American manufacturer of pressure washers and generators.

Coleman Powermate owns all rights to machines associated with them, such as Gasoline Generators, Air Compressors, Pressure Washers and Water Pumps. The company is subsidiary owned and headquartered in Marietta, GA, USA.

Bottom Line

Generators can indeed come in handy, especially in areas where power outages occur frequently. Similarly adding a wheel kit makes it easier to move your generator around, making it more practical and convenient.

And although installing one may cost you some money upfront, the result is worth it.

Before getting started on your project, make sure to do some research. If all else fails, use our step-by-step guide as a template for making your generator wheel kit.

This video can also help

About Steve Stuart

Steve Stuart is an electrical engineer who developed interest on generators during his school years. After school, he became a generator enthusiast. This is after encountering power supply problems at the area of residence where he lived. Power would be on and off and so food would go bad and the room heater would go off especially during winter. After trying the different generator brands for several years, Steve now provides information on the available brands and products in the market today. Based on his experience, he gives the do’s and the don’ts when it comes to generator use.

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