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Test small.jpg



The engine and gearbox are among the most important elements required from the bike.

The seat [1], fuel tank [2] and exhaust silencer [3] are removed followed by the front wheel and the steering mechanism [4].

Removing some components like the radiator can be messy, requiring draining before removal.

Remove the air intake, filter and shroud protecting the rear suspension elements.

The majority of the easily accessible components have now been removed.

The seat mounts and other unnecessary frame sections are cut away.

Sharp burrs and other sharp edges are ground flat.

The frame now has the minimum number of members to maintain structural integrity.

The carburettor is removed.

The cylinder head has been removed and the piston head is being detached from the connecting rod.

The engine without the combustion chamber, fuel distribution and ignition components.

The right side of the engine houses the clutch [1], the water pump [2] and the oil pump [3].

Removing the left hand engine cover to access the generator and the final drive sprocket.

Removing the cover reveals the generator [1] and final drive sprocket [2].

The generator housing was cut to assist removal.

The generator is pulled off its tapered shaft.

The tapered mount is taken from the section cut from the generator body. This will become the interface point between the bikes mechanical and the electrical conversion systems.

The rivets holding the remains of the generator housing and the tapered mount are drilled through.

A larger bit is used to drill out the rivet heads.

Any rivet heads that cannot be drilled out are ground away.

The two elements, the tapered mount [1] and the generator housing [2] have now become separated.

The tapered mount [1] needs to be attached to the gear [2] driving the final electrical generator.

The tapered mount is secured in the lathe chuck [1] in preparation for removal of the locating stub [2] .

The tapered mount has been faced on one side, so it is flat and perpendicular to the axis in which the tapered shaft will fit.

The hole positions on the tapered mount will be transferred onto the gear and drilled through to fasten the two elements together.

The rear wheel is removed to allow the hub to be separated easily.

The spokes are cut and removed from the hub.

The stripped hub is remounted onto the rear forks and the chain tensioned by adjusting the hub position and locking it in place with the tensioning screw [1].

The exposed engine is covered to prevent the introduction of debris which could hinder the smooth motion of the mechanism.

The electricity generating motor [1] requires an interface plate for mounted onto a housing. This can be machined from a material with good mechanical stability like nylon 66 [2].

A piece is accurately machined and parted off from the round bar of nylon.

The pitch circle diameter (PCD) of the studs on the motor is measured with digital calipers.

The PCD of the motor is transferred onto the machined nylon interface plate and drilled.

The interface plate is bolted onto the motor.

The nylon interface plate is trimmed.

The sander is prepared by setting it to 90 degrees.

The interface piece is sanded accurately.

However, a more efficient motor has been acquired and a new mount is designed.

Nylon spacers are machined to fit around the studs which formerly held down the cylinder head.

The spacers allow the motor to be fitted at a suitable height.
The motor housing is adjusted to enable the gears to mesh together.

When the appropriate height has been established, the housing is bolted on with wing nuts.

The stripped motorbike chassis, modified to drive a gear which turns the motor, generating electricity from a descending weight. The final assembly before testing.