Grateful acknowledgement to Dixie Sheet Metal of Falls Church, VA fora donated stomp shear cut of 6x12 inch 0.080 6061-T6 aluminum even as they turned down rolling the 6x12 blanks to 4 inches OD.
I'm off today on the Y20 Metrobus to All-Metal Fabricators in Chantilly. It's a one-way commuter bus, and I have to grab a cab to Fair Oaks hospital to get back in time for an appointment near home. AMF's roller is 4 inches diameter so with springback the part will be oversized but that's OK, it gets hose clamped to size, and perhaps someone will come along with a smaller roller.
The part is a motor mount for a world's most powerful bicycle generator, some hundreds of watts. A four inch diameter, five inch long Ametek servo motor rated 30 VDC, 12 A stall and max 12 A before demagnetization begins is chain driven from the left side of the rear wheel with bicycle chain using a Big Cheese BMX spider bored to 33 mm by Jensen after I drilled it to 1 1/4 inch with a Unibit starting with the 7/8 given hole bushed to 3/4. The Big Cheese accepts all standard 110 mm BC 5 position chain rings and is fitted with a 48 T steel ring right now. The Big Cheese bolts to a disc brake hub.
A Molex connector rated 8 amps connects various loads to the generator. One load is a Radio Shack inverter and various com and nav projects are proposed at110 VAC.
I was having chain drop problems but didn't realize until the chain climbed and broke my 4 inch plastic drain pipe motor mount that the 8 tooth pinion needed to be beveled. I beveled the teeth and wire brushed them until they were smooth.
The motor mount hangs from the seat stay clamp bolts on the generator development platform, a 2004 Lightning Cycle Dynamics Thunderbolt recumbent bicycle, behind the seat. A hose clamp tensions the motor against the pull of the chain. Another clamps the mount around the motor, adjusting its alignment with the drive cog. A tab and screw secure the motor to the mount. It fell out once when there was no tab.
In front, a ceiling fan motor has been fitted to the cranks for use as a self-excited induction generator but development cannot proceed until the DC generator is back on line as a motor to drive the AC generator. It's a question of matching a capacitor to the winding. I got a five minute run out of it the other day but then went to test the DC generator and inverter, had the chain climb, and lost the motor mount. A 6V/2A / 12V/2A / 12V/10A 12V/50A battery charger / booster powers the motor.
A cigarette lighter socket plugs into the Molex connector, as does a pair of battery clamps for the battery charger. The inverter plugs into the cigarette lighter socket. I've previously ignited and enjoyed a cigarette with the energy from this motor.
Another similar motor has a rivet nut on the back to support the end post of a cigarette lighter socket that will be supported by a conical plastic shell. I'm having a little trouble riveting the stud on that to the clip that retains the lighter. It's a bimetal lamination and you can't just braze it on the stud. It will be more compact, though, and there's a little 6 VDC regulator on the motor back shell for a 7.2 W Nite Rider bike light to be added later. TI donated that regulator.
A rare earth mix white fluorescent lamp marks the front and a yellow aperture tube, sample C provided by Voltarc, marks the rear. The fixtures are Wolo FL-44 AA cell lamps sold for lighting closets in RVs.
I tolerance everything and tolerate everyone. I love: Dona, Jeff, Kim, Kimmie, Mom, Neelix, Tasha, and Teri, alphabetically. I drive: A double-step Thunderbolt with 657% range. I fight terrorism by: Using less gasoline.