Build A Wind Power Generator Build A Wind Power Generator

What You'll Need
Wood for 3 to 3.5-foot blades
Screws
1/4 -inch lead wire for balancing blades
Heavy duty truck fan
Magnets - 10 1/2 inches-by-1 inch-by-6 inches
Bearings (2)
Wire - 5 lbs. of 21 awg copper
Digital tachometer (for testing)
The Blades

Consider harnessing windpower to produce clean, safe, cost-efficient energy for your home.
 

Choose the wood that you’d like to use for the blades. The best kind of wood to use is quarter-sawn Sitka spruce, but it can be hard to obtain.

Once you have your wood, use a template to carve it. First, cut the wood with a band saw, and then use your template as an outline, to hand carve the shape that you want.

Next, secure the blades to the hub with the screws.

Finally, use a few coats of an oil-based primer followed by several more coats of oil-based epoxy resin high gloss enamel.

You must properly balance the blades in order for them work properly and effectively. Take them inside, or wait until there is not any wind and the air is still. Apply a series of weights and sheets to each of the blades and the alternator. Spin the blades and let them come to a complete stop. The one that ends up facing south will be the heaviest blade. Repeat the process and keep adding weights until the weight is evenly distributed throughout the turbine.

The Generator

After you’ve balanced the blades, you’re ready to get your generator. Start off by taking a trip to your local junkyard. Generators for windmills can be difficult to find. Check closely for the RPMs of each generator. While the number varies, around 300 RPMs is ideal for this type. Once you find one, replace all the bearings.

Magnets

The turbine will only send power to the battery once a specified MPH—called the 'cut-in-speed'—is reached. You want to maximize the turbine output without sacrificing or losing wind speed.

To make the cut-in speed lower, you need to increase field strength with magnetic poles. You may have to create platforms for the magnets so that they perform properly. This part is tricky because you must place the magnets precisely to interact with the other parts, and you also need to place them in certain degrees aligned with north and south. The magnets will be placed based on alternating poles.

Rewiring and Finishing the Generator

Next, you’re ready for the big job of rewiring the generator to suit your needs. Turn the copper coils about 60 times with a 21 gauge wire. Wiring the generator will take a lot of twisting and hammering to get them to stay solidly in place.

Once you have all the pieces assembled, make sure that everything is balanced and is securely in place, filling in any gaps in between the running parts. Once your generator is finished, test it thoroughly to make sure that everything is balanced and the magnets are calibrated correctly.

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