Westerbeke 15kw BTDC Failure

During this summer mid-season the electrical end of my generator failed and was only putting out 9volts AC. Being it was July I spent a couple weeks as time allowed trouble shooting the issue and after trying a new rectifier and a few other inexpensive parts the message from those that work on these daily, was that the electrical end had failed. The quotes I received for a new electrical end were all around $4k. I quickly decided that if I was going to be removing the generator it was a one way trip given the age and hours. I initially was set on getting a Northern Lights but the space Cabo has for built in generator enclosure made the width of a 12kw NL an issue. The math just didn't work. So I considered the 9kw but given loads the boat runs even at a managed usage I didn't feel the 9kw was adequate and then there is the issue that they are currently not available in the US with no timeline known of when they will be certified and available again. I briefly considered a few other brands but it seemed all my research led me to Phasor. I was skeptical at first but the factory was easy to work with and given I had no dealer in my region and was planning to self install they sold to me directly which was nice. I compared a few different models and spoke to some east coast installers about what they had been installing in Cabo's.
I decided to order an 11kw upgraded to 24v with remote oil kit. Engine is a 3 cylinder Kubota with LINZ electrical end. Oberdorfer water pump. All the parts to make it a generator seems like good brands. While they were building the unit I got underway removing the Westerbreak. Used travel lift along with a fork lift that had 14ft knuckle. Chain fall on the end with some help maneuvering by yours truly. In an effort to have removal not become chaotic and take more time than needed we made a little set up while in the boat house to use a chain fall and beams to reposition the generator side ways on a temporary shelf so removal would be quicker once in the slings.
Removal went seamless and then I spent several nights removing existing sound deadening and cleaning up space before prepping cables for new generator. Once generator arrived from FL we set the pallet at a working level in the shop and went over everything and found some damage from the starter being swapped from 12v to 24v as well as during transport. The plywood shell around generator was knocked loose and had rubbed knocked a sensor apart and some wires were chaffed. Sent pictures to Phasor and they sent me new sensor and entirely new harness. Thankfully my dad is a retired machinist, he fabricated some parts for mounting remote oil kit on front of generator as well as some flat stock to mount generator to and thru bolt to boat for better mounting. I also ordered the optional gauge and start stop panel from Phasor. After removing the Westerbeke remote panel and looking at the Phasor I decided to reach out to Common Ground in California who did all the Cabo AC and DC panels. I drew up a new panel that they custom fabricated for me and then I moved all the toggles and gauges over to that custom panel to mount in the salon. There were a few quirks as it related to the Vetus air vent as well as the Vetus exhaust system. The air vent was set up for 3/4 hose and the Phasor had 7/8 connections. Making the change from 7/8 to 3/4 in brass or plastic wasn't appealing to me given all the raw water flowing thru hoses and also being in the enclosure in a place hard to see when in use. I decided to have some custom nipples fabricated from 304SS. On the Exhaust system I replaced the o rings for the Vetus and replaced the 2 inch Trident hose. Connection had to be made after generator was in place on back of the unit. For the fuel and oil hoses I kept existing as is on Cabo end and went to Industrial hose shop and purchased fittings to transition to what Phasor was set up for.
Project wrapped up right as our off season has arrived. Ran some test loads on generator and am very happy early on. Look forward to putting hundreds of hours on the new generator in the coming years I hope. Still bummed about timing of everything as it cost me my biggest trip of the year but it is what it is.

Mods perhaps after a few weeks in general Tech section you could move to Cabo Yachts forum as I know many others will have this same scenario in the coming years.

Addtl Photos

More Photos.

What size did you go with?

On this 11kw Phasor model the oil filter was on backside of generator on the right side. Would have been miserable to change filter. $150 remote kit with custom bracket my dad made and now I have oil filter, fuel filter, and water pump on front of unit with easy access. I also relocated fuse that was on the back of generator for starter to the control box over electrical end.
Gauges were not a choice of electronic vs analog. I think they intentionally keep electronic components to a min for reliability.

Sadly only 2200. Removed a bunch of parts off the dead Westerbeke and sold to a fellow Cabo owner on East Coast with same generator. The rest went to scrap yard.