How to Build a Weatherproof Cover for a PTO Generator Using an IBC Tote

Welcome back to Base Camp WNC! If you’re looking for a practical way to keep your PTO generator dry, this guide is for you. Today, I’ll walk you through the process of building a durable, weatherproof cover for your generator using an IBC tote. Keeping your generator dry is crucial, and this DIY project is a cost-effective solution. Let’s get started!

Why Build a Cover for Your PTO Generator?
Generators must be protected from moisture to operate reliably. In this setup, the generator sits beneath the drip line of a roofed shed. Using an IBC tote, we crafted a custom cover that fits perfectly over the generator. The tote is cut and modified to create a sturdy, protective enclosure.

Step 1: Preparing the IBC Tote
We started with a standard IBC tote and cut it down to size. Here’s how we measured and modified it:

• Measured 24 inches high, cutting below the middle rail to save it as the bottom frame.
• Cut two pieces to create the front and back sections.
• Joined the two frames using rebar as connectors, creating a snug fit between the pieces.

Step 2: Assembling the Frame
Once the pieces were cut:

• Measured and adjusted the width to 32 inches, ensuring enough clearance for the generator.
• Used self-tapping metal screws to secure the sides together.
• Reinforced the structure with ratchet straps, pulling the bowed sections into alignment. This method helped keep the frame tight during assembly.

To further stabilize the frame:

• Inserted half-inch rebar into pre-drilled holes for added support.
• Tackled alignment issues with tools like a splitting maul to ensure a perfect fit.

Step 3: Cutting and Modifying the Cover
The top section of the IBC tote was split to create a cover. Key modifications included:

• Cutting around the fill hole to fit snugly over the generator.
• Trimming excess material while leaving overlap for weatherproofing.
• Ensuring the cover extended 3/4 of the way across the frame for added protection.

The seams were sealed with silicone and secured with pop rivets and screws. This ensures the cover is both durable and weather-resistant.

Step 4: Painting and Final Adjustments
To prevent scratches and condensation, the inside of the cover was painted black. Additional steps included:

• Adding quarter-inch bolts to attach the plastic cover to the frame securely.
• Creating a hinged board to hold the cover open while plugging in wires.

Step 5: Installing the CoverWith the cover built and painted:

• Mounted the frame to the generator using four bolts for stability.
• Modified the hinge mechanism to fit around the tractor hitch, ensuring easy access.
• Added a drip edge to redirect roof runoff away from the generator.

Final Setup and Testing
The generator was hooked up to the tractor and wired for use. To prevent water pooling, we dug out the area beneath the roof and added gravel for proper drainage. The cover is now fully waterproof and user-friendly:

• The hinged board makes it easy to lift and lower the cover.
• The lid stays securely in place, protecting the generator from the elements.

Key Takeaways
This IBC tote cover is a cost-effective and durable solution to keep your PTO generator dry and functional. These totes are widely available and affordable, especially if they previously held non-drinking water.

Ready to Build Your Own Generator Cover?
If you’re inspired by this project and have any questions, feel free to reach out! Don’t forget to like, share, and subscribe to Base Camp WNC for more DIY tips and tricks. Thanks for watching, and we’ll see you in the next video!

If you have questions or are looking for homestead consulting services, please visit our site at:  CarolinaHomesteadPlanner.com.  We are happy to help