How To Make An Exhaust Extension For Your Portable Generator (For Under $20)

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

This is vital in cases of enclosed shops, having to bring your generator in the garage during a storm, or even using it in your RV.

A generator exhaust extension bolts to your generator’s exhaust and allows for 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 down with a clamp later on.

2. Determine The Length Of Extension That You Will Need

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

While this may differ from time to time, you will want to figure out the longest length you may 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

The type of extension you are going to want for your portable generator’s exhaust is “flex tube”.

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

You will need to find flex tube that both 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 them down 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 your 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 easily able to move the pipe around without the clamp moving. If it becomes loose, reposition and tighten again.

6. Route The Flex Pipe To A Well Ventilated Area

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

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

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

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, it will also increase the changes 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.

Can an Extended Exhaust Make A Generator Quieter?

It’s no secret that a portable generator makes a lot of noise. Most in the 70-80db range at the industry standard of 23 feet.

While at a jobsite or out in the open it may not be a big deal, but in a rural area such as a neighborhood, the loud noise of a generator can be a nuisance to your neighbors.

Not to mention, in a shop or garage, the sound could get magnified making it louder than usual.

There are many ways to help silence the exhaust including adding a muffler, adding a quiet box, and a few other MacGyver style ideas! I will touch a bit on this in another article.

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 down 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 a slightly higher or hopefully, a little less!

Ensure you are buying high quality parts that are made for exhaust circulation to ensure you 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 you been in that required you to extend your generator’s exhaust?

8 thoughts on “How To Make An Exhaust Extension For Your Portable Generator (For Under $20)”

  1. I have an RV which i want to build the chassis of a suitcase generator into the side of the RV in an enclosed ventilated box, and because the muffler runs pretty cool, route the exhaust gas outside the box to the main muffler from the RV engine using high temp silicone hose. Any thought’s?

  2. WHAT ABOUT INSULATING THE FLEX HOSE FOR PERSONAL AND FIRE PROTECTION. IF YOU HAVE EVER HIT THE MUFFLER OF A RUNNING MOTOR YOU KNOW HOW HOT THOSE THINGS GET.

  3. can’t find a 1 1/4″ ID flex pipe, at least 8′ long. Found this in 25′ lengths ! But the cost was too high. ($60 +). Need it for generator. $20 is just wishful thinking….

  4. I have a Honda EU3000is portable generator and the way the muffler is made, I wasn’t able to add an extension pipe. I’m interested in either the Generac XT8000EFI or Honda EB 10000W, but I’m not sure if the Honda will take an extension. The Generac looks like it would be very easy however.

    Would doing this allow me to put the generator in a shed and run the exhaust outside?

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