120 Volts DC Bike Generator Parts List
Even though it's DC, this generator can be used to power AC appliances such as compact fluorescent lamps, tube fluorescent lamps, sewing machines, blenders, coffee grinders, food processors, juicers etc.
The appliances can be found at resale shops for less than $10. If it works it will not damage the appliance (famous last words). We caution not to try any AC appliance that is worth more than $10. You can put a fuse on the appliance to protect it. The only appliance destroyed so far was a small coffee grinder. We were pedaling very fast (producing around 200 volts DC) when we turned on the grinder. The lesson learned was to turn on the load (the appliance) before starting to pedal.
A generator that appears to be the same as the one we use (ours was from a discarded treadmill) can be acquired from Surplus Center in Lincoln, Nebraska.
The V-belt and sheave (pulley) are from Grainger. You may need to wrap aluminum flashing on the shaft for a tighter fit. Take the generator with you when you go to Grainger to fit the sheave and pulley.
You will need to set up a commercial account at Grainger by showing a business card and a company check. Or you can have a friend with an account get the parts for you.
Use a small V-belt sheave (around) two inches. The smaller the sheave the higher the rpm and voltage. One can put the sheave on the threaded part of the shaft instead of the smooth part. In either case you will need to flatten the shaft slightly with a file or grinder for the sheave set screw.
The v-belt should be around 88" to go around a 26" wheel and the pulley. The formula is pi times the wheel diameter or about 3.2 x 26 = 83" plus room for the sheave (88" or more).
A bed frame (found in the alley) is used to get the bike frame off the ground. Notches are "carved" in the frame for the wheel's axles using a hand grinder. You can also find bicycle trainers for less than $100 at Target online. These will also get the rear wheel of the bike off the ground.
