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Newbie questions on ultra low cost frame building for pedgens in low income countries

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Newbie questions on ultra low cost frame building for pedgens in low income countries

Old 07-18-15, 12:21 AM
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Newbie questions on ultra low cost frame building for pedgens in low income countries

Hello everyone,

After 28yrs military and then almost 5 years contracting in Afghanistan and Bahrain I am moving on. My wife and triplets are in the Philippines. I am starting a business there now and have a workshop where I'll be upgrading beyond just some simple welding and woodworking tools. I'll be getting a CNC plasma cutter table, MIG welder, large compressor, and generator and start building axial flux alternators starting with designs from Hugh Piggot from Scoraig wind and the Dan's from other power. Magnets are en-route to build my first prototypes. So, why am I posting here is because I want to build frames for the pedgens at low cost and know nothing about frame building.
I have been considering sourcing parts on alibaba such as cranks so that I'll only need to build the alternators and frame itself. Any help and advise in design and sourcing parts will be greatly appreciated as there will be lots more mistakes without your help. My original design goal was to build for under $100 but if not possible then want to build as low cost as possible. Ultimately, there likely will be two models for one that is reliable but lowest possible cost and other that is a higher cost version. For example, I may use a C8 ferrite design alternator with a little less efficiency but lower cost in one model and an N42 neodymium model with nicer crank set and other parts in the higher priced version.
Building a spin bike frame for one type and a reclined version for the lower cost version also is a possibility.

Best regards,
Mike
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Old 07-18-15, 12:35 AM
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I'm not quite sure what you're asking. Somehow you're jumping between bicycles and alternators (car parts?) and magnets.

Anyway, for your low cost bicycle build, I'd look at purchasing generic straight tubing and direct tig welding it. For example you can buy bulk chromoly 4130 steel tubing, and shape and weld as needed.

Cheaper still would be some high carbon/high tensile steel tubing purchased in bulk.
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Old 07-18-15, 02:59 AM
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Hi CliffordK, I am only asking about the frame building portion as I can handle the building of the alternator no problem. Is there an ebook available on the subject? Since this is a stationary exercise bike weight is not an issue so chrome moly is going to be out for even a more expensive version I'm thinking. The kinds of things I was wondering about is where do I get the round piece that the crank goes into and a matching crank? Is that a standard size? How about bending handle bars or do people normally just buy that part? Sorry to be such a newbie but I'm only interested currently in building a frame for the exercise bike that will be a grid tied pedgen. I hope to open a green or ecogym once I get several of them made and then eventually make them available to anyone who wants to buy them. There is one person making such a thing but I've researched efficiency on the alternators used and it is miserable. This is where mine will be much better at 90 percent efficiency. Also, I will need to match the sprockets for the target rpm of 90 for a human on the pedaling to be converted to the correct rpm at the alternator. The cheapest design using ferrites puts out 100w at 240 rpm or a ratio of 1:2.6 at 90 pedaling rpm. The neodymium's can do 90 percent.

Best regards,
Mike
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Old 07-18-15, 05:46 AM
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Oh... generator... I missed the pedal-gen part.

As far as things like the bottom bracket shell, they can be purchased from any frame building supplier.

STEEL LUGLESS SHELLS :: BOTTOM BRACKETS :: Nova Cycles Supply Inc.

They usually come pre-threaded, but it is common to at least chase the threads after welding/brazing. The old "one piece cranks" use an oversized bottom bracket shell, and are unthreaded.

Many fine threaded bike parts such as steer tubes (Not necessary for a fixed bike), and potentially the BB shell are threaded on a lathe rather than using taps and dies. If you find the right tubing size, you should be able to make your own.

You can bend tubing to make things like handlebars, but it certainly is worth considering just buying them (bulk?)
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Old 11-03-15, 09:50 AM
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It might be beneficial to consider the generator as one function of the frame set-up and make some of them that can be converted to a bicycle when transportation is needed.

Perhaps the ability to bolt on a water pump for a dug well might be considered if that is also a need in the area in which you are working.
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