Hi Matt, I haven't read the whole thread because the subject doesn't grab me, but I think you're a true PBO and you and your son have had fun with the project. Good on you. I remember in David Sinnett-Jones book about his RTW trip in Zane Spray he had a little Mase generator to charge his batteries for radio usage. ISTR he had problems with the engine/genny linkage because of vibration, but I'm sure there are modern couplings that will cope with that. Good luck with your project.
The sign on my cabin door says 'Not enough bucks stop here'