Wallfish

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.

I just use my fingers. Wind a bunch of wraps then pull on it so it tightens up the coil then pinch it tight again and repeat as many times as it takes. The factory new spring retainer is a piece of steel shaped like a C which keeps it tight in a package and makes then easy to install. You can make one out of a 1/8" sliver of 2 inch pipe. I think even PVC pipe would work. Wind the spring by hand, then let it uncoil into the C shaped retainer. That way it can easily be placed into the recoil housing. Then the retainer is removed while holding the spring down in the housing with your thumb. Let it uncoil slowly in the housing until it's tight

Sorry, I did post a pic of the pieces. You should have a 3 piece muffler now so the piece in the center is the spacer and they can be stacked as many as you want

Stack spacers Cone piece on the exhaust collector, spacer, spacer spacer spacer spacer (How ever many you want) then the face piece.

There's one cap that has the face with the little holes and the rest are the spacers with bent tab holes at the bottom. You can stack as many as you want but you'll need to make a threaded rod piece for whatever length you stack them to retain it. You can typically find longer screws at the hardware store and just bend the end like the one that;s on there now. Pretty sure the thread size is #6

Tiny Tiger Generator Operating Instructions Models 5001-1 & 5001-2-1.pdf

The 2 small posts are already 12v DC. They were mostly used to run the 12v electric starters for RC stuff but it should also work to charge 12v batteries as well. Manual here file:///C:/Users/urema/OneDrive/Desktop/Tiny%20Tiger%20Generator%20Operating%20Instructions%20Models%205001-1%20&%205001-2.pdf Those small mufflers can be stacked but finding them at a reasonable cost may be difficult. Lots go missing because people take them off and don't put them back so everyone is always looking for mufflers and air cleaners.

Yours is a model 350? Like pictured above? That style is quieter than a 300 is. The 300 just used the common little black mufflers/spark arrester. Are you using that for camping or something? Like the outboards do, if you run a metal hose from it into a bucket of water all you will hear is water bubbling so maybe you could experiment with that????

The Tiny Tiger model 350 used a different style muffler. Or search on epay for 2 stroke muffler and maybe adapt one.