Step 2: Rewiring

In order to get the optimal voltage output from the generator, you need to re-wire the windings of the stator. I used the instructions from this website:
They are using the motor for a wind generator, but the idea for the bike is the same. I had a 42 pole stator and rewired it in 3 phases of 7 groups of 2 poles for a 24v configuration. I know that sounds kind of confusing, but read the website carefully, it's very informative and isn't too hard to follow once you get the basic concepts down. 

Before reattaching the stator to the shaft housing, I cut the shaft off 2 1/4" from the housing, or about 10 1/2" overall. Next I fitted the chainring cassette over the cut end of the shaft. The ID of the cassette was slightly smaller than the OD of my motor shaft, so I had to machine it down a little bit. If you know anybody with a metal lathe, take it to them, but the method I used also works in a pinch. I clamped the shaft housing in my bench vise and put my electric drill on the threaded end. While the shaft was spinning I was able to evenly grind down the diameter of the cut end of the shaft with an angle grinder. Sorry I didn't get a photo of this.
<p>Hi, Andrew, my question is what does 'UPS' stand for in your article? I know it's not united parcel post. LOL</p>
Hi Joel, no I guess that would be UPP. Un-Interruptable Power Supply in this case. :)
I don't think i can get that kind of motor here in nigeria, or is there any idea of how it can get to me here?
awesome info! I have this exact motor and the 24v ups in the garage wired up to 2 old car batteries. Thank you for posting the link to rewire the thing. I was trying to figure out how to use the high voltage output but, now I don't have to. I rewired a microwave transformer with a new 6ga primary winding. the output was 5v and 40amps with a brisk hand spin.
Great, sounds like you've got everything you need! A transformer would certainly be another way to do it, 200W is pretty impressive!
I like this. I could use this to power a motor that would drive a crank-powered washing machine! Save money from going to the laundromat and get excercise too!
This is so cool, I had to tweet it!
hi Andrew,<br><br>here in the Philippines, we do not have that kind of motor, all washing machine and likewise dryers are using capacitor type induction motors..how ever i found out that food mixers or juice mixers like the ostirizer/B&amp;D brand uses a brushed dc motors like that of portable 220v electric drills. i assume it also can do output a voltage powerful enough to charge a car battery. will try out soon.<br><br>also portable battery powered electric drills or screwdrivers can be used..
my buddy own an appliance store in iowa and this type of motor is not common but not as rare as people think. they are out there, i have 2.
Thank you for this. Here in the USA our washing machine motors appear to be a good deal different than the one you show from New Zealand. Ours are capacitor start squirrel cage induction motors, usually single phase. I always wanted to do something like this, but envisioned using a 12 volt automotive alternator to charge a lead-acid battery connected to a 12 volt DC to 120 volt AC single phase voltage inverter. My idea was to power a small TV so I knew the program would soon go &quot;off&quot; if I stopped pedaling.
Hiya Phil, thanks for the comment! Yeah induction motor washing machines are plenty popular here too. Randy of randysworkshop.com fame claims to have a shipment of motors in the US and he's selling them for $105 apiece, which is quite a deal considering they're new. <br>Your idea doesn't sound too dissimilar from mine, although I wouldn't recommend using an auto alternator unless you can spin it at the thousands of RPM it's designed for. The beauty of the smart drive is that it can be easily re-wired for different applications. Try this link : http://www.thebackshed.com/windmill/articles/gettingstarted.asp<br>about halfway down the page they discuss different types of motors.
How much current does this produce, you may have said but I did not see it.<br>
it depends, how hard can you pedal? The way I have it set up, it's just trickle charging a battery bank, so it depends mainly on the capacity of your batteries and their state of charge, i.e. how much you are trying to draw from them at the same time as you're charging them

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Bio: I work in IT, but enjoy a variety of things. I'll usually do something until I'm almost good at it and then move ... More »
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