Build a Personal Power Plant

 
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Preparation of the Generator

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parts list
frame, wheel, and crank
generator
platform
mount everything!
display board
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Depending on whether you purchase the generator new or rebuilt, it may or may not have come with a locknut or woodruff key. Both are required to mount the pulley to the shaft of the generator. Note that there is a shaft extending from each end of the generator. The pulley will be attached to the end with the two threaded terminals.

Begin by placing the woodruff key on the shaft. Next, wrap the shaft and key with 4 to 5 layers of cellophane tape (it may be necessary to clean the shaft with solvent to remove any oil that may prevent the tape from sticking). Now press the pulley onto the end of the shaft lining up the key and keyway. Thread the locknut onto the end of the shaft and tighten. Then tighten the pulley's setscrew onto the woodruff key. Here is a picture of the assembly:

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