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Build Your Own 150W Pedal Power Bicycle Generator Stand




 

 

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

 













 

 

Tools Needed to convert your bike trainer stand to a pedal power bike generator.

 

Item Description Price
1 Milwaukee 1/8" Drill bit for making holes in bike generator training stand. This is a 1/8th inch drill bit to make a small pilot hole in your bike generator stand. Milwaukee 48-89-1525 Twist Drill Bit 1/8"
$2.30 + shipping
2 This is a 3/8th " drill bit to use after you make the pilot holes. Milwaukee 48-89-1805 Cobalt Twist Drill Bit...
$6.03 + shipping
3

I love this drill, it is variable speed and reversible direction.  Well made, well designed.  I don't like cordless drills for some reason, they just seem too weak when you need them to kick in a little horse power.

Makita 6407 3/8 4.9amp 2500rpm Vari-speed E...
$88.33 + shipping
4

For cutting the threaded rod and square tubing

 DEWALT DW3970 12" High Tension Hack Saw Frame
$19.95 + shipping
5 File - for de-burring the threaded rod and square tubing  
6

For tightening the rubber roller set screw on the generator shaft

 Bondhus 12138 Set of 10 Hex L-wrenches, Lon...
$3.70 + shipping
7 Hack saw blade Molybdenum High Speed Steel Hacksaw Blade 1...
$4.57 + shipping
8 Wire strippers for wires on generator motor Klein-KurveŽ Wire Stripper/Cutter for S...
$18.10 + shipping
9 Heat shrink gun Master Appliance 35017: Master Heat Shrink ...
 
10 Soldering Iron Weller SP40L Marksman 40 Watt Soldering Iron
$13.85 + shipping
11 Solder .031" (0.8mm) 60/40 SOLDER 1 LB.
$6.95 + shipping
12 Optional AC inverter to make 110AC volts for TV or computer Dual-outlet Dc-ac Power Inverter
$48.90 + shipping
13 Wire connector Crimper CRIMP TOOL FOR .093" PINS 24-14 GA
$16.90