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Step 4 - Remove Rubber Retaining Ring From
The
Ascent Magnetic 3 Level Trainer
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Step 4 - Remove Rubber Retaining Ring From
The
Ascent Magnetic 3 Level Trainer
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Step 5: Cutting Your Super Strut / (AKA Universal strut or Uni-strut)
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Step 5
If you don't want to buy your Super-strut
off the web, you can drop by the local bricks and mortar hardware store like Home Depot to pick up what you need.
Make your way through the tumult to the electrical area and find the spot shown in this picture "HERE" . That is the Superstrut rack section.
Pick yourself out a fine straight piece of Superstrut and try to make it out the store without mishap because it's really long and awkward to carry around the store, and if it happens to drop on the floor on accident like it did with me, it's so loud that people will hear it from one end of the store to the other.
Since you are working to achieve a small energy foot print and trying to conserve, you probably drive a fuel efficient car like a 1990 Honda Civic. This can present a challenge when you try to go to Home Depot to get your piece of Super Strut. Namely because it only comes in 10 foot lengths. You can see the piece below balanced on the shopping cart with the Honda Civic in the background.
At this point you reach into your front seat of your ride and grab your trusty hack saw.
After about 100 strokes of your mighty blade, the Super Strut yields and you emerge the victor.
NOTE: the piece you cut has sharp edges that can cut your hands. Handle with care. Bring a file with you to file off any sharp burrs that are there. Now you can easily load the Superstrut into your car and head home.
Now cut two 24" long pieces of Superstrut.
Next cut a 9" piece of super strut
Step 6: Drilling 1/2" Holes In Superstrut
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Step 3a - Mark your hole locations
Step 3b - Drill your 1/2" Holes
You have three options for this step. (1) Use a small drill press to make your 1/2" hole (2) Use a hand drill to make your 1/2" holes (3) Get some one else or machine shop to drill your 1/2" holes.
If you use option (1) or (2) read the safety instructions in the manual that came with your tools. You are liable for injury or damage caused by your failure to comply with safety and operating guidelines of your tool.
Option(1) is the best in my opinion. For those of you whose modus operandi is to constantly try to justify buying more tools for your garage (like me) now is the opportunity to get a small drill press for $85 at your local hardware store. A drill press is nice because it drills straight through the Superstrut. With a hand drill this is a little harder. Note that the holes need to be straight through the Superstrut or your pieces will look crooked when they are mounted to the stand.
For this step you have to drill completely through both sides of the Superstrut. If you choose your drill press, set it to low speed. Don't press too hard. It should take about 1 minute per hole. NOTE: The tills (shavings from the hole) are HOT! You must wear safety glasses when doing this. You could get small piece of metal in your eye like I did on another project. It caused a rust ring in my eye and I had to do to the eye doctor to get it out.
Use a larger bit to scrape the sharp edges from the hole. If you don't have a larger bit, then use a hand file.
Step 7: Assemble the Superstrut frame
Step 8: Mount the 14.8 Volt DC Alternator
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Drill mounting holes in L-Brackets for 68 AMP Car Alternator
Put the L Brackets on the Alternator as shown below with a 3/8" bolt or threaded rod.
Side view of the 9 Inch Long Superstrut Alternator mount -cross piece
Leave all the mounting bolts hand tight for now. You will need make adjustments to optimize belt tightness and rear tire alignment.
Step 9: Putting belt on your rear tire
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Turn your bike upside down and remove the rear tire. The ascent bike stand comes with a spare quick release axle. It has hardened ends in the optimal shape to fit with the Ascent Bike stand. If you quick release axle has plastic ends, don't us it! Use the axle that comes with the bike stand.
NOTE: Make sure that your quick release handle is on the opposite side of your wheel that your gears are on. It must be that way to work in the Ascent Bike Stand!
Remove the tube and tire from your rear wheel so it looks like this. You can leave the rubber liner thing on if you want. It doesn't seem to make a difference.
Now put the belt on.
Put the wheel back on the bike frame.
Make sure the wheel is equi-distant from the frame. This is a very common mistake. Notice in the picture below how the gaps between each side of the wheel and frame are the same size. you need to do the same comparison check.
Step 10: Mounting Your Bike To the Ascent Magnetic 3 Level Trainer
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Follow the instructions that came with the Ascent Trainer
Unscrew the tension knob out all the way
Insert the axle end first that does not have the handle on it as shown below.
Adjust your quick release handle so that it is on the top of the axle. Next adjust the landing cup of the bike trainer so it's wide opening is also facing upward. This will allow you set the axle end right into the cup as you tighten the tension knob.
Step 11: Aligning the belt to the wheel
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Now you need to align the Alternator to the rear wheel.
In this picture you can see the belt is not aligned, it is too far to the right.
Since you only hand tightened the bolts, you can know adjust the car Alternator as shown below. By doing a proper alignment, you have a more efficient bike generator because there will be less friction. And it will keep the belt from jumping off when you are pedaling.
Don't not start pedaling until you have a load or a large capacitor on the Alternator . It may cause damage to it. Congratulations, you are know half way done!
Step 12: Electrical Wiring to the
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Prepare the In-Line Fuse Holder wire by crimping on a 1/4" inner diameter ring terminal on one end and a female spade connector on the other. Next prepare a 9 inch black wire with a large 3/8" inner diameter crimp terminal ring on one end and a crimp on male spade connector on the other. These need to be YELLOW which means these connectors are rated for high current up to 20 Amps.
Use lock washers when you put these on to help make sure they don't get loose.
Make sure you have a 20 Amp Fuse in the fuse holder. This 12 AWG wire is only rated for 20 Amps. So do the right thing and play it safe. Even though the fuse holder comes with a 30 Amp fuse it's not ok to use it.
Step 13: Assembly of Digital Capacitor and Cobra 800 Watt Inverter
