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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

 

 
































 

STEP 1 - DIY BYO - Drill holes in your bike generator pedal power stand

 

Step  
a

Create a pilot hole centered on the vertical support as shown above.  It will be 7/8" distance above the horizontal support bar and your hole.   Use the 1/8" drill bit to create a pilot hole because it is much easier to start a hole than the 3/8" drill bit.  

WARNING: the drill bit will tend to want to "walk" on you.  It will move off of your mark. You need a very sharp, very pristine drill bit that will begin it's drilling immediately and not "Walk" on you.

b After the first hole, then use the 3/8 bit to go clear through.
c After the 3/8" hole is drilled on your bike generator stand, it has  VERY dangerous pieces of share medal around it.  They are often razor sharp.  You must ream out the hole to remove these sharp peices of metal using a 1/2" drill bit, or a file.  TRUST ME They will cut you when you least suspect it. GET RID OF THEM!
d The box shroud on this motor / generator will not be used.  Remove the box shroud (shown below).  You will need to take out two Phillips head screws to take the shroud off.

Move on to Step 2

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