Thanks again for all the advice!

Here's an update so far....

1. I was unable to locate 9 volt muffin fans, at Comp USA or Home
Depot. Will order two on-line and likely install them near the power
outlet and the carb intake. In addition, we plan on installing two
louvered vents and drill some more holes on the side of the cooler.

2. I ran the genny on medium load for 20 mins. while it powered a
ceramic heater for the cockpit.
We were in a now wake zone which enabled me to hear it. There was no
problem. The lid was partially opened. The temperature inside the
cooler was 151 degrees. Near the exhaust, the side of the cooler was
hot. I could put my hand on it for just two seconds. However, no sign
of melting. Is this too hot of an enviroment?

3. Per a poster's suggestion, I put a thick bathmat under the cooler.
This helped dampen the sound and vibration considerably.

4. I don't have any CO concerns. The exhaust is right by the engine
vapor vent which always stays on while the genny is running. However,
Regal has a CO detector in the cockpit and cabin.

5. Many have warned me about liability....thank you. At this point,
my concern is with my own genny. I will have to be certain it works
before promoting the design, via a paid download, or manufacturing one
for somebody else. Regardless, I will not make a penny. This is for
my stepson. I've been accused in an unmoderated forum of spamming. If
this was true, then why would I post clear pictures of the design and
list all the materials. Again, I want this to work for my own boating
needs. If this enable another to solve their genny problems, then I'm
tickled. Feel free to copy and tinker with this all you want.

Finally, I was heartened by the experience of a Bayliner owner, who
writes the following about his own experience......

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"I built a sound box for my Honda 2000i out of a plastic storage tub
with a top. Cut out a section for the exhaust end to stick out and an
opening to put the cords through and a chain to lock it (Genny) to the
step just in case a person came by and created a wake and we started
rocking and rolling. I have put it on the swim platform and found it
better to be on top of the roof (Hardtop and I realize a lot of folks
couldn't do that). All I did was get a rubber door mat and fit it under
the Genny on the bottom of the tub and it wraps up about a 1/3rd of the
way up each side and this has cut the noise down at least 1/3. It also
took away a lot of the vibration noise that you get through the boat. I
have used it in very hot weather running for a few hours with no
problems. Also has been in rain and the Genny stayed dry. After 3 years
I have no complaints or any problems other than the plastic box has
gotten old and I lost the top one time in a high wind storm. I 'm
currently working with a fabricator (good friend) to make one out of
aluminum that is hinged and will fold up for storage. It will have
louvers on each side and similar to the plastic box an opening for the
exhaust and the other side for the cords and chain. It will be lined
with 3m soundproofing material same as used in engine rooms. We have
been kicking around putting a small electric fan in it that will run
off the one outlet I don't use. And this will draw in air. Honda made
the Genny for camping and other applications and wanted to keep it
light. I think one can improve on making it quieter with some form of
sound box that Honda would approve of as long as it gets enough air to
keep it cool.
In the plastic box and on the roof (hardtop) I thought there would be a
lot of vibration and it would be louder. It actually is very quiet when
we go below and close up the hatches to watch a movie, heat the water,
run the microwave. The other nice thing with it on the roof, it lowers
any problems of Carbon Monoxide coming into the cabin. I also point it
away from other boats that may be anchored next to us and it reduces
any sound for them too.

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Count me as one who is interested!!!

-Greg