Build a Personal Power Plant

Mounting the Bicycle Frame, Generator/Regulator, and Seat	back to the start! parts list frame, wheel, and crank generator platform mount everything! display board
	Step 5 of 6

The key to successfully mounting the bicycle frame and generator is aligning the frame and generator pulley along the centerline of the platform. Snap a chalk line down the center of the platform to help line these components up. Mark the forward position of the bicycle frame assembly on the platform. Hold frame against the mark and line up the centerline of the frame and the centerline of the platform. Trace the two mounting hole locations (these should land over the 2X4 mounted to the center of the platform). Drill the holes just marked (3/8" diameter) and counter bore them on the bottom side of the platform (1" diameter approximately 3/4" deep). Mount the frame using the two 3/8 X 3 ^1/2" bolts putting the washers and locknuts on the bottom side. Here is a picture, although this design uses only a single piece platform (ignore the mounted generator for now).

If the rear derailleur was removed, replace it now. Then take the 86" belt and pass it over the rear bicycle rim (as if it were a tire) and set the wheel in place on the rear fork carefully routing the chain through the derailleur and over one of the rear sprockets. Fabricate the frame supports from 14 gouge sheet steel being sure to deburr and radius all sharp edges and corners.

Completely remove the nuts on either end of the rear axle and attach the frame supports, securing them with the axle nuts. When tightening the axle nuts, be sure that the wheel is centered in the rear fork. At this point, route the chain so it runs over the largest sprocket at the pedals and the smallest sprocket on the rear wheel (the rear derailleur spring will naturally pull the chain this direction).

Now drill holes in the side of the platform, using the holes in the frame supports as guides. Secure the frame supports to the side of the platform using two 3/8 X 2" bolts, washers, and locknuts. Here you can clearly see the frame and the frame supports, along with the generator and chair that will be mounted momentarily.

Mounting the generator and regulator will require the three 5" hose clamps, the 9" section of shelf ladder material and the appropriate socket or wrench (for tightening the hose clamps).

Begin by propping up the end of the platform that has the slots cut into it (1 ft should be high enough). Next, slip two of the hose clamps over the generator with the screws resting on the "top". Now set the generator on the platform allowing the hose clamps to drop through the slots. Next, reach underneath the platform and slip the section of shelf ladder material through the hose clamps where they hang below the platform. Tighten the hose clamp closest to the center of the platform so that it is just snug. See the next two figures for a view of this assembly.

Top view of generator and hose clamps (Left) and underside view of shelf ladder material. Notice that the "corners" of the shelf ladder face down and the "edges" contact the underside of the plywood to reduce the likelihood of slipping.

With one hose clamp snug, it is possible to wiggle the generator towards the bicycle frame. Before slipping the belt over the pulley, slide the third hose clamp over the pulley end of the generator and up to the center hose clamp (it may be necessary to loosen the center hose clamp to do this). Note that if the belt seems tight, slip it on the pulley first and then work it around the perimeter of the wheel.

The regulator mounts by slipping its flanges under the two loose hose clamps. Now snug up all of the hose clamps (do not tighten). Using a rubber mallet, square up the generator perpendicular to the bicycle frame and line up the pulley and bicycle wheel. This is best accomplished by tapping both on the generator and the shelf ladder under the platform. When the alignment is acceptable, tighten all of the hose clamps (see the next figure).

Regulator mounting (note location of three hose clamps)

To mount the chair, first remove the rubber or plastic feet from the front legs of the chair. Next, drill a hole in each leg, 1/2 inch from the bottom of the chair.

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Set the chair on the platform so that the front legs rest on the steel angles. Insert the lynch pins through the angles and the holes in the chair.

To adjust the chair, remove the pins and move the chair forward and backward. Be sure to replace the pins after adjusting (see the figure below).

Top view of seat adjustment mechanism. Adjustment pins are used on each side to hold seat stationary.