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Originally Posted by sanddrag
Do you think I should gear it 1:1 or gear it up or geat it down. I think the peak HP rating on the welder is at about 3300 RPMs (I don't remember exactly but it was around there).
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Sanddrag, do you mean peak HP for the engine is 3300 rpm? If so, you have one of your numbers down. Then you just need to gear the alternator to the engine, gearing the alternator to go faster than its normal speed. This way you get the maximum power out of the alternator, since you are running it closer to what a car revving hard would be. However if you gear too high, the alternator provides too much resistance to the engine, so your engine runs at below max power. Its tricky work. To tell you the truth I'm not entire sure what to tell you, since I dont know the power curves of the engine and alternator.