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FREE BUILD YOUR OWN GENERATOR PLANS

 

     

 

 

 

 

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FREE BUILD YOUR OWN BICYCLE GENERATOR CHARGING STATION PLANS

 

Specifications: 15 Volts DC, 20 Amps DC Peak,  300 Watts Peak

 

Use these free videos and plans to make your own pedal power bicycle generator station.  Good for powering up your television while watching your favorite show.  

 

This power generating system is also great for emergency survival backup generator power.  Pedal Power is one of the more reliable and consistent forms of alternative energy because solar panels can get blown away in a storm and only work during the day, and wind turbines only spin when there is wind.

 

If you are interested in buying a bicycle generator already built, then click here

 

Use this bike generator station to power radio, cell phone, blender, laptop, wheat grinder, Christmas Tree, LED

 

 

 

PEDAL POWER GENERATOR KIT - EASY STEPS  (Takes One Hour To Assemble)

 

These steps can be carried out by school / classroom students or the average do it your selfer type individual.  If you buy the kit you will only need a screw driver, wrenches, wire cutter, stripper, and crimper, and volt meter. 

 

If you are trying to save $ and make the kit parts from scratch, you will need all the tools mentioned above and a drill press,  drill bits, taps, terminal blocks, crimp on terminals, metal cutting band saw.   

 

 
 
DIY  STEP 1 INSTALL THE ADAPTER RISER  BLOCK

When you get your stand you will see a friction roller mounted on the bracket.  This friction roller is for exercise workouts and is just a waste of energy.  It just converts energy from your body to heat.    You will need to remove this friction roller before you install the riser block.    

The riser  adapter block installs as shown below.  There are two 16mm bolts (1 Inch Long) that secure the block on the sides.  This block is made of aluminum, but could be made of had plastic or steel.    If you bought the kit, then the two 16mm bolts will come with the kit.

If you want free make your own riser block instructions then click here

 

 

DIY STEP 2 INSTALL THE SUPPORT BAR

For this DIY STEP you will need a 5/16 wrench or 11mm wrench, and two 1/4 -20 bolts with 1 inch length.  Also a flat washer and lock washer.  These come in the kit so if you bought that then you don't have to worry about getting them.

If the free do it yourself plans to make your own support bar then click here

  

Use a 5/16 wrench to tighten down the support bar.  The bolts are 1" long

 

 DIY

STEP 3

INSTALL THE BICYCLE GENERATOR PLATE

You will need two 1/4-20 bolts for this DIY STEP -1 inch long.  Also needed will be a flat washer for each bolt, and a lock washer for each bolt.  If you want to make your own plate then send an email along with your organization and a project description to brad@mns-power.com  and I'll give you the dimensions.   You will need to use an 11mm wrench or a 5/16 wrench to tighten down the generator plate as shown below.  This DIY STEP takes about 2 minutes.  If you have purchased the kit, you will be able to use the bolts that are included inside.

DIY BYO MYO Bicyle generator adapter plate- pedal power   Do it yourself bike generator system - generator mounting plat

 

 DIY  STEP 4 INSTALL THE BICYCLE GENERATOR  

Below you can see how to install the generator.   This generator comes with a pulley that takes a 3/8" wide V-belt.  It also takes 6mm mounting bolts.  

       

 

At this point in the project you can hook this generator directly up to a $40.00 shop VAC for a floating ping pong ball display.  The stinger shop vacuum from home depot only cost about $40.00.  If you plug the hose into the blow hole of the shop vacuum and get a ping ball, the ball will float higher and higher in the air as the person riding the bicycle generator pedals faster and faster.   Both kids and adults really like doing it!  This display gets people thinking about alternative energy and for that reason it is a great thing to setup on earth day or other types of green events.   

To make it an educational exhibit, you can hook up a WattsVIEW sensor and then your computer can project Volts, Amps, and Watts for people to see!.  Go to http://wattsview.com  for more information on that.

Questions?  Send an email to brad@mns-power.com

 

 

 DIY

STEP 5

MOUNT THE CHARGE CONTROLLER

At this point, only if you want to use your bike generator to charge batteries or a powerpack, you will need to install a charge controller.   There are two screws that mount the NC25A Charge controller to the aluminum plate as shown below. 

Learn More About How the Charge Controller Works & Why it's used

PayPal $139

 

Buy from Amazon.com

 

 

 

 DIY  STEP 6 INSTALL TERMINAL BLOCK 1

There are two 6-32 machine screws that are used to mount terminal block one to the generator plate.  These are included in the kit.  If you buy the plate already made, the holes are already pre drilled and tapped so the screws will juts go right in.  If you want to make your own  generator plate then end an email to brad@mns-power.com

 

 DIY  STEP 7 CONNECT POSITIVE GENERATOR LEAD TO TERMINAL

For this step you will connecting the positive RED wire from the generator to the 1st screw terminal of  the generator output block as shown  below .  You will need

  • Size 12 AWG wire

  • Butt Splice or wire nut

  • Wire  cutter

  • Wire stripper

  • Small crimp on ring connector or fork connector

  • Crimpers.   

You can see that a butt splice is used to make the wire long enough to reach the terminal block.  You could also use a wire nut instead of a but splice.

 

 DIY  STEP 8

ATTACH GENERATOR POS. VOLTAGE TO CHARGE CONTROLLER INPUT

 

Cut a 8.5" piece of wire.   Strip the end, and crimp on a connector.  Below you can see how to attach the red size 12 AWG wire to the 2nd screw terminal of the terminal block. Next  you will strip the other end of the wire and connect the wire to the input terminal of the charge controller as shown below.  You will need a small flat head screw driver to tighten the screw. 

 

After you have tightened the wire, you must perform a tug test on the wire.  Pull firmly on the wire and make sure it doesn't slip out!   It is very common for beginners & even experienced electricians to under tighten screw terminals.

 

 DIY

STEP 8.5

INSTALL TERMINAL BLOCK #2

Install the 2nd terminal block as shown below.  The holes are already drilled in the aluminum plate.

 

 DIY

STEP 9

INSTALL THE THERMAL FUSE

A thermal fuse gets hot when too much current is flows through it and then opens up until you stop pedaling.  This is called an OCP or over current protection device.   After 20 seconds the thermal fuse will cool down and the pedal power system will be ready to use again.  This fuse should never trip an if it does, it means there is something wrong with your wiring.   The thermal fuse is an off the shelf part and costs about $0.99 US    You can order this part from http://digikey.com

Part number:

507-1325-ND

 

You may want to crimp on two fork connectors onto the legs of the fuse (showing in red below).  When you are done with this step it should look like this.  

 

 

 

 

 DIY

STEP 10

ATTACH GENERATOR GROUND WIRE TO TERMINAL BLOCK 1

For this step you will be lengthening the negative (black) wire from the generator so it reaches the terminal block as shown below.

bicycle generator negative wire instructions step DIY generator

 

 

 DIY

STEP 11

You will need to make up a 6.5 inch black size 12 AWG  as shown below.

 

You will be putting two connectors unto the same screw terminal.  Unscrew the terminal enough to accommodate the two connectors.  Then tighten them both down firmly. 

   

 

 

 DIY

STEP 12

ATTACH CAPACITOR AND NEGATIVE LEAD TO CHARGE CONTROLLER TERMINAL

Now route the wire installed in the previous step to the far right terminal of the charge controller.  You will also need to slide in the terminal of a 100uF 63 Volt capacitor.  Be careful, if you put the wrong lead in, it will destroy the capacitor.  Install it as shown below.  The purpose of the capacitor is to keep the mechanical relay inside the NC25A charge controller from being damaged if some one gets on the bike generator and starts riding fast without any electrical load hooked up to the generator. 

Still don't understand?  Send an email to brad@mns-sales.com

If you order the kit this capacitor will come with it.  Or you can order it from digikey for $2.00 

 

 DIY  STEP 13

 

ATTACH POSITIVE WIRE TO OUTPUT OF CHARGE CONTROLLER

     

Next you will need to route this wire over to terminal position 1 but don't tighten it all the way.  In the next step you will be adding a 2nd wire to this terminal.

 

 

 

 DIY  STEP 14

 

ATTACH POSITIVE BATTERY SENSE WIRE AND CAPACITOR
Prep a 9" 14 AWG red wire by cutting it to length and crimping a fork connector as shown.

 

Attach the crimp connector to terminal 1 as shown below. 

 

When you are done, it should look something like this. There are two connectors on top of each other.

 

Now attach the other end of the wire to the 2nd terminal from the left which is the positive battery monitoring terminal, along with the capacitor lead.  Make SURE to do the tug test and pull on each wire to make sure it is firmly seated in the terminal and properly tightened down.

 

 DIY  STEP  15

ADD ZIP TIES FOR WIRE MANAGEMENT

   

 

 DIY  STEP 16

INSTALL VOLT METER TEST PROBES

 

 

 DIY  STEP 17

PERFORM GENERATOR VOLTAGE OUTPUT TEST

After you have attached the volt meter and turned it on. Make sure it is set to DC voltage.  When you turn the motor with your hand in the clockwise direction, you should see a positive voltage read out on the volt meter.  This tells you that your generator system is working correctly. 

 

 

STEP 18

 

 

 

  

 

REMOVE THE REAR TIRE FROM YOUR BIKE

INSTRUCTIONAL VIDEO

 

  • Remove the air from your rear tire by using a pressure relieve style pressure gauge or using a small screw driver or nail (see video). 

  • Release your rear brake cable so that the break pads open up wide and allow you to remove the rear wheel.

  • Now that the tire is completely flat and removed from the frame, use the tire levers to remove the rear tire from the rim.  (see video for more details)

  • Remove the tube and the thin rubber band that runs all around your rim covering the ends of your spokes.  If you don't take this off, it will break and get tangled in the pedal power bike generator drive belt.

  • Now that the rear tire is off of the rim,  install the rear wheel back onto your bicycle frame. 

 

 

 DIY  STEP 19

INSTALL BLOCKING DIODE

 

INSTRUCTIONAL VIDEOS

PART 1                                            PART 2

 

 

If you want to store your energy into a battery or powerpack, you should use a blocking diode.  If you want to learn why take a look at the explanation at http://blockingdiode.com

Strip and crimp generator side of diode.

 

Attach the generator side of the blocking diode to the generator output terminals.  Strip and crimp wires to a cigarette lighter plug.  Put on crimpers as shown in this photo. Connect the diode to the powerpack as shown.
 

 

 DIY  STEP 20

 

INSTALL BIKE ON STAND

 

INSTRUCTIONAL VIDEO

 

Before putting your bike on the generator stand, retract the two clamps as shown in the photo. Now put your bike onto the generator / trainer stand.  Take care to align the wheel with the pulley as best as possible.  See the red arrow in the photo.  Tighten the clamps down as hard as you can.

 

 

 DIY  STEP 21

 

 INSTALL BELT

 

INSTRUCTIONAL VIDEO

 

 

 

 DIY  STEP 22

 

HOW TO VERIFY IT'S WORKING

 

INSTRUCTIONAL VIDEO

 

 

 

                  TEST RESULTS                SCHEMATIC

 

 

PARTS FOR 300 WATT BELT  DRIVE BICYCLE PEDAL POWER GENERATOR

 

GENERATOR $99

 

WIRING KIT $39

 

ADJUSTABLE LENGTH V BELT

3/8 INCH WIDTH  $69

 

      EXERCISE STAND   $99

 

 

 

or

Buy from Amazon.com

or

 

 

 

BLOCKING

DIODE $79

CHARGE CONTROLLER $139

Learn More 

or

Buy from Amazon.com

 

 

 

ADAPTER

RISER BLOCK  $39

 

SUPPORT BAR 

$39

 

 

GENERATOR MOUNTING PLATE   $59

 

 

Buy A Generator System Already Assembled  

 

 

 

SCHEMATIC

 

 

 

PART ACCESSORIES TO BUY       

 

 

BATTERY POWERPACK

Portable powerpacks give you a great way to store and use your energy wherever and whenever you want.  

If you already have a 12 Volt lead acid battery or a power pack / inverter of your own, then you don't need to buy this.  

If you are into emergency preparedness and want to have emergency backup power, then this is a great solution for you.  For those of you have a years supply of wheat, you will be happy to know that you can run most wheat grinders off one of these power packs.  (pedal power wheat grinder or human powered wheat grinder) Take a look at the power pack owner's manual to see how long different things will last when plugged into the AC 1110 AC inverter.

 

 

 

 

 

 

 

 

RECOMMENDED:

The Duracell powerpack  has a 28 Amp Hour battery inside of it and also a radio, flash light , jumper cables, and a 110V AC inverter which allows you to run your laptop, television, or blender. So for those of you new to this stuff that means that this magic box converts 12 Volts DC into 110 Volts AC which is the same kind of electricity that you have coming out of the wall plug of your house if you live in the U.S.A.

Click HERE to read the owner's manual with Duracell 600 specifications.

 

 WattsVIEW 3.0 Power Monitoring Software

Learn More

 

  

 

12V REGULATOR

 
 

You may want to use this 12V DC regulator if you are trying to power an AC inverter or trying to power up CFL light bulbs or LED bulbs.  You can adjust a trim pot resistor to change the output of this regualtor by ± 4 Volts dc.   You can also use it to charge a lead acid battery.   Some people prefer this DC to DC regulator over the charge controller.

 

DC to DC Voltage Converter / Regulator

Input:  Up to 60 Volts

Output: 14.4 Volts  (Adjustable ± 4 volts)

Up To 20 Amps Output

(With Over Current Protection)

 

 

$259

 

 

 

 

 

                  

TERMS & CONDITIONS                                                

  1. By following these FREE DIY BYO plans you agree to not operate this pedal power generator around small children or any individual who might stick their fingers in the wheel, chain, sprocket, or belt while it is moving.

  2. You also agree not to allow anyone near this bike generator with long hair or loose clothing that could possibly get it stuck and pulled in to the belt / chain / wheel assembly while being operated and cause injury or death.

  3. Also, By following these DIY STEPs, you assume all liability and responsibility for owning and operating you own pedal power bicycle generator.  You also agree to have a licensed electrician check over your assembled unit to make sure you have not wired up something up incorrectly BEFORE you hook it up to any kind of high power devices such as battery packs or lead acid batteries.  Also, before you charge a Powerpack with your pedal power bicycle generator, you will read and understand the safety section of the owner's manual. 

  4. You also agree to send me a photo of your final project to share with others on this web page.