Wallfish

Yes. Anything to hold the rope as long as it gets locked on the spool

The wire needs to be bent in such a way to feed both ends of the wire through the holes from inside of the spool out. The factory pieces resemble 1/2 a paper clip and the wire is kind of soft

With a little bit of fuel in the tank, connect a piece of fuel line to the nipple and blow into it. The one that bubbles the fuel is carb line.

Yes, one nipple will just suck air and the other has a stem to the bottom for fuel pick up

The shape of tank. The line from one side to the other allows air to escape out the top. Otherwise the opposite side from the fill neck would just remain an air bubble on the top without it. So that line allows it to fill all the space so the tank holds more fuel

You can get the 2 sections off without removing that hole plug cover

Better to just remove it and repair the wires as no doubt they are crusty dry and brittle. Remove the rear two sections at once and the wires stay

Interesting. Turbair made them with O&R engines but that's what I believe to be a Japanese knock off engine of an O&R. Very nice find. Yes, it's probably oxidized points contacts preventing the spark. You can find a few threads on the Turbair Tot in the Ohlsson & Rice section Here's mine

Carefully check where that wire was repaired. It's difficult to open that crusty stuff up without cracking more but just go slow. Solder with a solder gun and not a torch Check the other wires too as once you open it up and move them the insulation cracks easy.

The winding wires of the generator without anything connected to them. You should be able to figure out if something is shorted or if the wire is broken and not making a complete circuit. Then you can verify through the AC plug as the wires connect directly to that. Systematic detective work going through each circuit to hunt down where the issue is. It appears there are 2 separate set of windings. One for the AC and the other for the DC. Verify you are connecting the correct wires to each. Was the 12v DC working but not the AC?

That old epoxy is always cracked and brittle so moving the wires can expose the copper wire and cause a "short". Maybe use a meter to confirm the windings are not shorted to each other. Have someone look at this wiring pic for you. It's an open generator with the wiring

I've received them shipped both ways. Full unit in a large box and partially disassembled to fit in a smaller box. Never shipped one of those but i have broken down large tools and shipped in a smaller box. I

No slack at all. the "epoxy" or whatever it is holds and isolates the winding wires. You can pick it out carefully and solder the wire back but be sure to cover it again. Something like liquid electrical tape should work.

You guys should communicate through private message. Use the little envelope button in the top right corner and you can message directly with each other without including everyone else. The forum threads are for sharing information with others but private sales do NOT concern others. Please use PM. I'll delete most of this thread but give you time to figure it privately before doing that.

Here's the recoil rebuild tutorial which might be helpful.