Brian, when I was installing the old 5k system 12 years ago, I was totally with you on the cost of transfer switches. I had spent a couple years researching ways to get it done without the cost but even going with a DPDT switch from an electrical supply house was expensive.

I ended up building my own switch from components purchased at Home Depot, using a face plate mounted slider, similar to the one pictured in post 41. All together, it was about $75 for the little 4 space box, a 30A breaker and a 100A breaker. In my system, the transfer switch box was ahead of the feed to the main house breaker box.

You could save the extra expense by simply adding the breaker to your existing box and incorporating the slider which I believe is the way you're thinking anyway.

As for your question on the generator leads, it's hot, hot, neutral, ground. Some codes require separate feeds in the breaker box. If they're tied together in your box, you can join them, if not, you have to keep them separate.

__________________
-Evan


Benz Fleet:
1968 UNIMOG 404.114
1998 E300
2008 E63


Non-Benz Fleet:
1992 Aerostar
1993 MR2
2000 F250