How to Build Your Own Pedal Power Bicycle Generator

Alternative energy is an issue for everyone as we face higher oil prices and bills shoot through the roof. Building some innovative power generators at home might be the next best thing to electric cars. In this article you’ll learn how to build a pedal powered bicycle generator. With this generator you could charge up your car battery or just about anything else.

Things You'll Need

• Cobra 800 Watt Inverter
• Generator Rubber Drive roller
• Travel Trac Century Fluid Trainer
• 14 Amp Permanent Magnet generator
• Heat Shrinks
• Extension plug/cord
• Drill
• Wire Strippers
• Crimps

Instructions

Learn to generate your own electricity on a bicycle

1. First you will have to drill some holes. Start by locating the vertical support bar of the trainer stand. Drill a hole with a 7/8" bit in the outer side of the trainer stand. Make sure you are using a sharp enough drill bit to cut through the metal or the drill will wander off and could harm you. After you drill, remove the drill bit, and replace it with a 3/8" drill bit. Drill through the same hole one more time to clear it out.

2. File off the remaining metal bits surrounding the hole.

3. Remove the box cover from the motor.

4. File down the burrs on the ends of the mounting bar. These are very sharp. Be careful. Cut the mounting bar exactly in the middle so that you have two halves of the same length.

5. Cut two square tubes so that each one is 6" long. Sand down the burrs.

6. Add flat washers on the rod coming out of the stand. Attach the square tubing to the rod. Place containment nuts on the ends, then add lock nuts to secure the hold.

7. Mount the generator on one of the square tubes. Slide your square tube into the rod by turning the square tube upward. Attach the generator to the other square tube.

8. Install some spring supports on the ends of the square tubes, so that the springs touch the ground. Install the set screws in the roller housing unit. Slide the roller onto the shaft. Tighten the screws.

9. Cut the extension cord that you will use to connect to the generator. Strip the ends of the wires on the generator.

10. Tip the ends of the wires with a bit of solder.

11. Cut some heat shrink to fit over the wires (1.5" x 0.25" [l x w]). Slide the heat shrink over the wires of the extension cord and the generator wires.

12. Solder the wires leads together. Then use a lighter to melt the heat shrink. You can use a heat gun if you have one.

13. Strip the wire on the extension cord and apply a crimp. Slide the crimp connector onto the wire. Pull and test the wire to see if it holds strong.

14. Now you need to set up your power meter and charge controller. For this step it is important that you consult your owners manual for implementing the power meter and charge controller. Close all wiring. Place a bicycle on the stand. Run the pulley belt to the bicycle.

15. Connect low voltage drop-out to battery, and connect the out put of the low voltage drop-out to the inverter. You can now use the inverter to hook up other things to your generator.

Tips & Warnings

• If you are not an expert with tools or electric construction, you would benefit by working with someone who is an expert with electricity or electric construction. It is best not to work alone. Have first aid available, as some of the materials are sharp.

Resources

• Read this Article in Spanish