Build Your Own 150W Pedal Power Bicycle Generator Stand

 

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OBSOLETE

These Free DIY BYO Plans are now being replaced by these plans which are much more simple and cost effective.

 

 


 

 

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 3 - Cut your Square 1.25" x 1.25" generator mounting tube

bike generator square tubing for mounting genetator motor

 

Step  
a

Measure 2 6" lengths of 1.25" x 1.25" square tubing from Home Depot or Lowes.
b Make a distinct mark using a black permanent marker.
c Cut the bar using a hack saw - warning you must read the safety documentation that came with the hack saw to make sure you don't injure yourself.
d Remove the burrs at the end of the tubes.  THESE are SHARP and will cut you badly!!  Use a file or 100 grit sand paper to round off or "smooth" the ends.  THIS IS A SAFETY RISK.

Go on to Step 4

bike generator picture using dc permanent magnet motor  drilling holes in bike generator to mount dc permanent magnet motor bicycle generator dc motor mounted to trainer stand