Free DIY Bicycle Generator Plans

FREE DIY VIDEO PLANS / INSTRUCTIONS FOR DO-IT-YOURSELF

12V Bicycle Generator Emergency Backup Power System

DIY Video 1 Pedal Power Generator

Step 1: Installing Generator & Plate

DIY Video 2 Pedal Power Generator

Step 2: Connecting to Blower & Light

DIY Video 3 Pedal Power Generator

Step 3: Installing Charge Controller

DIY Video 4a Pedal Power Generator

Step 4a: Installing Blocking Diode

DIY Video 4b Pedal Power Generator

Step 4b: Installing Blocking Diode

DIY Video 5 Pedal Power Generator

Step 5: Verifying It Works

PARTS
(Numbers on image match to items listed below.)

Parts

 

 

1

Duracell 12V Battery Power Pack

 $190

Duracell 12V Power Pack ORDER
2

DC Generator    Video

(This is a permanent magnet DC motor that works as a DC generator)

 $199

Generator Dynamo DC Permanent Magnet Motor with Pulley

Bike Generator

 ORDER
3

Adjustable V-belt 80″ Long

$129

V-belt used with bike generator pulley system

V-BELT

ORDER
4

12V Charge Controller

$113

NC25A Charge Controller 12V battery charging

NC25A

Order

HERE

5

Aluminum Adapter Plate

Step 1: Installing Generator & Plate Make your own

FREE

DIY plans

——–

Call us for ordering information

6

Bell Motivator Trainer Stand

$29 to $80

(Used)

Bike Trainer Pedal Power DC 12V Generator

Generator Stand

Sold HERE
7

Blocking Diode

Watch Video demonstration

$99

Blocking Diode used for blocking current flow from the battery back into the generator

Blocking Diode

Sold HERE

Terminal Blocks Thermal Fuse & Wiring Kit for charge controller

Learn more

Call us to get availability Wiring kit for charge controller

 

This pedal power generator stand can be used by small children on small bikes or by adults on full size bikes. See test results info below for benchmarking information. This data was recorded using a WattsVIEW power monitor while charging a 12V Deep Cycle Duracell Battery Powerpack during a one-hour charging session. For more information see the FAQ WEBPAGE. If you want to buy a generator stand you don’t have to put together then take a look HERE.

 

BENCHMARKING/TEST RESULTS

Test / Benchmark Results

Volts / Amps

Test / Benchmark Results

Watts

Test / Benchmark Results

Calories / Watt-hours / Amp-hours

Specifications

Dynamo Model ASE-300-DC
Output Voltage Range 0 to 40 Volts DC
Nominal Current Rating 15 Amps
Peak Current Rating 20 Amps
Peak Power Output (Charging 12V Battery) 300 Watts (15V x 20 Amps)
Drive Type 2″ Diameter Pulley
Peak Operating Temperature 100℃
Cooling Method Air-cooled
Shaft Bearing Type Ball Bearing
Mounting Bolt Size 6 mm
Wire Lead Length ~12″
Wire Lead Size Size 12 AWG
Approximate Weight ~8 Lbs
Number of Poles (Brushes) 4
Generator Type This is a DC permanent magnet motorbeing used as a generator.
Peak to Peak Voltage Varies depending on RPMs (See this output waveform)
Voltage Output Vs. RPM Voltage Curve Graph
Rated Operating Speed 2800 RPMs
Internal Resistance ~ 0.35 Ohms
Dynamo PM generator internal resistance bicycle generating for different currents

Dynamo Internal Resistance

Typical Amp-hours During 1 Hour of Use5 to 10 @12VTypical Power During 1 Hour of Use100 Watt Hours (0.1 KWH)

Do-it-yourself Bike Generator Wiring Kit for Charge Controller

If you want to charge 12V batteries or a 12V powerpack, you may want this wiring kit which includes wire, terminal blocks, thermal fuses, and mounting screws as shown in the video. In order for you to use this wire kit, you will need to get a set of wire strippers and wire crimpers.  Call for availability.

Wiring kit for charge controller

Click image for full view

SUGGESTED TOOLS & ACCESSORIES

Description Cost Amazon PayPal
Digital Multimeter
(Very helpful to have!)
Digital Multimeter $12.73 Order
Wire Crimpers / Cutters Wire Crimpers / Cutters $19.93 Order
Wire Strippers Wire Strippers $12.80 Order
Tire Levers Tire Levers $5.00 Order
Regular style fuse holder for cars. Get a 20-amp or 15-amp fuse from your local auto store. FUSES – You can easily use a regular 20-amp fuse from AutoZone or any other auto store, or you can use a thermal resettable fuse. The video instructions show a thermal fuse being used in Video #3. You can use either option. If you purchase the wiring kit you will receive the resettable fuse for your generator. Bike Generator Fuse $3.51 Order
A thermal fuse gets hot when too much current flows through it and then opens up until you stop pedaling. This is called an overcurrent protection device. After 20 to 200 seconds, depending on how hot the ambient conditions are, the thermal fuse will cool down and the pedal power system will be ready to use again. This fuse should never trip, but if it does, it means there is something wrong with your wiring. Thermal Fuse $19.00