PROJECT

STEPS

Intro

Buy Major Parts

Buy Small Parts

Tools Needed

1-Drill Hole

2-Cut Threaded Rod

3-Cut Square Tubing

4-Install Rod

5-Mount Generator

6-Generator Part 2

7-Install Supports

8-Install Roller

9-Install Tire

10-Cut Wire

11-Strip Wires

12-Tin Wire Ends

13-Cut Heat Shrink

14-Apply Heat Shrink

15-Solder Wires

16-Use Heat Gun

17-Strain Relief

18-Crimp Terminals

19- Power Meter

20-Battery System

Small Parts to convert your bike trainer exercise stand to a bicycle generator

 

Item	Description	Qty	Link to Amazon.com and Pricing
4	You only need 10.5 inches of this threaded bar.  You will have ~25 inches left over.	1	Click here for details 5/16-18 3' THR ROD 18-8 S/S Pkg Qty. / 1 $4.20 + shipping
5	Set screws needed to secure the Generator rubber roller.   You need 2 of these	2	Click here for details Alloy Steel Set Screw Hex Socket Cup Point ... $1.30 + shipping
6	Wing Nut to act as a lock nut for the bike generator threaded rod.     Bag of 10 but you only need 3.  You will have 7 of these left over.	3	Click here for details Nylon 6/6 Wing Nut 5/16-18 (Pack of 10) $3.70 + shipping
7	The Leeson generator PM motor has 4 of 0.25" tapped holes for mounting. You will need 4 of these screws to mount the bike generator correctly.	4	Click here for details 100PK 1/4-20x2 FH Screw $5.63 + shipping
8	Flat washers are needed on the bicycle generator trainer stand to reduce friction caused by lateral forces.	4	Click here for details Stainless Steel ANSI Flat Washer #3/8 Narro... $6.55 + shipping
9	These nuts are used with the wing nuts to secure the ends of the treaded bar on the bike generator trainer stand adapter.   Bag of 100 but you only need 3.	3	Click here for details   5/16-18 HEX NUT ZINC Box Qty. / 100 $2.80 + shipping
10	This is heat shrink Needed to cover the solder connections to the generator - Leeson Motor	4 Inches	Click here for details   48' HEAT SHRINK TUBING WRAP SLEEVES ASSORTE... $8.99 + shipping
11	You need a smooth tire if you want the rubber roller  to last a long time and wear as evenly as possible as your making human  power with the bicycle generator.	1	Click here for details   Cheng Shin Street Tire 26 x 2.125" White Sk... $10.00 + shipping
12	1.25" x 1.25" Square Bar from the local hardware store.  This has 1" spacing on it.	12 inches	$5
13	1/4"  Carriage Bolt 4" long used to support the generator PM motor firmly against the bike tire.  You can get these from your local hardware store for $0.50 cents each.	2	1/4 X 4 CARRIAGE S/S Box Qty. / 25 $12.70
14	You need 2 springs with a length of 2 3/8 inches.  The spring needs about a 3/8" inside diameter to work with the 1/4"  Carriage Bolt.  It has about a 50lb / inch spring constant.  I bought this spring assortment from the hardware store for about $3.00  It had 6 of the  springs I used shown on the left being held in my hand.   It's called the #1 Assortment from Century Spring Co.	2	Century Spring Co. Spring Assortment, No. 1 $2.87