How to Make an Exhaust Extension for Your Portable Generator (For Under $20)

Last Updated on July 25, 2022 by Manager Access

In many situations, you will want to vent your portable generator’s exhaust away from your work area to a better-vented area.

This is vital in enclosed shops, when bringing your generator in the garage during a storm, or even for using it in your RV.

A generator exhaust extension bolts to your generator’s exhaust and allows your exhaust fumes to be routed outside of your working area.

These can be bought online in a kit for your RV, but for portable generators, you will have to get a little crafty. Luckily, I am going to show you how to make an exhaust extension for your portable generator for under $20.

1. Find the Diameter of Your Generator’s Exhaust

To ensure that you are going to have a secure connection from your exhaust extension to your exhaust, you will need to measure the diameter of the portable generator’s exhaust.

You can use a ruler or tape measure to measure across the exhaust tip and add about ¼” to ensure a slip fit from your extension to fit over.

You will secure it with a clamp later.

2. Determine the Length of Extension You Will Need

In order to properly extend your exhaust to a more ventilated area, you will need to determine how long your extension must be.

While this may differ from time to time, you will want to figure out the longest length you could need and buy accordingly.

You can find extension material in lengths of 6 feet up to 50 feet to fit your specific needs.

3. Find Exhaust Flex Tubing to Fit Your Dimensions

For your portable generator’s exhaust, you will want “flex tube.”

Flex tube is metal tubing made to be flexible for easy routing.

You will need to find a flex tube that fits your needs for fitting over the exhaust pipe and reaching to a vented area.

4. Get the Correct Size Clamp to Secure the Flex Pipe

To properly secure the flex pipe to the exhaust, you are going to need a pipe clamp that is made to fit your diameter of piping.

Pipe clamps can be found in all diameters to suit your application.

Most require a simple socket to tighten, so be sure to have one on hand.

Hose clamps can be used if your pipe allows it, but a pipe clamp will be your best bet with flex tubing.

5. Secure the Flex Pipe to the Exhaust Pipe

Now that you have your flex pipe and clamp, you can place the clamp onto the flex pipe and the flex pipe over the exhaust pipe.

Tighten the clamp down firmly to make a leak-free connection, but be sure not to damage the exhaust pipe.

You should be able to move the pipe around easily without the clamp moving. If it becomes loose, reposition and tighten it again.

6. Route the Flex Pipe to a Well-Ventilated Area

Now that your portable generator’s exhaust extension is installed, you can route the extension to a well-vented area.

This can be outside of a window, under a garage, or any other area that allows you to position your extension to properly vent your exhaust.

You will want to avoid letting your pipe make its way back into your area, so securing it will also help make sure it stays in place and exhaust fumes are not entering your workspace.

7. Disassembling Your Exhaust Extension

When you are finished using your generator, you are going to want to properly disassemble your exhaust extension for proper storage to prevent damage.

Leaving your extension on your generator will not only make storage difficult, but it will also increase the chances of damaging your newly built extension.

Unbolt the exhaust extension at the generator exhaust pipe and properly store your extension with your generator or generator accessories.

Key Take-Aways & Wrapping it up

• Always measure out your needed parts to ensure a tight-fitting connection
• Buy high-quality, exhaust-specific parts for added safety and longevity
• Make sure your exhaust extension is tightened properly to prevent leaks
• Make sure your exhaust extension is properly routed to a well-vented area

The importance of routing your exhaust is vital to keep you and others safe when operating your generator in close quarters.

This also allows you to bring in your generator during bad weather, such as a rainstorm or snowstorm that could potentially damage your generator (see this post about rain covers).

Always make sure you have a very tight connection and that your exhaust is being vented to a well-vented area.

So there you have it, 7 easy steps to extend your portable generator’s exhaust for less than $20.

Depending on your application, pricing may be slightly higher (or, hopefully, a little less)!

Ensure you are buying high-quality parts that are made for exhaust circulation to keep you and your generator safe.

I want to hear from you! Have you had to build an exhaust extension for your portable generator?

What other situations have required you to extend your generator’s exhaust?