Food Living Outside Play Technology Workshop

DIY Wind Turbine

by DIY Dave on August 17, 2011

Table of Contents

DIY Wind Turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Intro: DIY Wind Turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Step 1: Parts & Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Step 2: Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Step 3: Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Step 4: Backbone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Step 5: Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Step 6: Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Step 7: Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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 Author:DIY Dave
"Can't" can't do anything until "try" comes along and does it

Intro: DIY Wind Turbine

This instructable will demonstrate how to build a power generating wind turbine. My inspiration came from seeing other wind turbine instructions online. I hope to simplify
the process with clear, easy to follow instructions.

Thanks to mdavis19 for his instructable How I built an electricity producing wind turbine which really sparked my interest in wind energy.

http://www.instructables.com/id/DIY-Wind-Turbine-2/
Step 1: Parts & Tools
Parts
Battery - - - $58
Battery Box - - - $8
Battery Connectors - - - $2.25
500 Watt Inverter - - - $45
Generator - upcycled treadmill motor - - - $0
Tail - scrap metal - - - $0
6'' PVC pipe 10' length - - - $30
Bolts & Screws - - - $5
1'' Iron pipe 60'' length - - - $14
Pipe Nipple - - - $2.50
Pipe Flanges - - - $8
Pipe Swivel Connector - - - $3.50
16 Gauge Wire (already owned) - - - $0
Black spray paint (already owned) - - - $0

Total - - - $176.25

Power tools
Drill & drill bits

Jig saw

Table saw

Belt sander

Hand tools
Various screw drivers
Tap set
2 pairs of Channel Locks
Protractor
Measuring tools (I used a tape measure and a caliper)

Step 2: Motor
The most important part of this project is the electric motor. Luckily, I had a nonworking treadmill in my garage just waiting to be scrapped out.

DC motors, when turned, will generate current. Be sure the motor you plan to use is DC powered, and it's helpful if it has a flywheel attached.

http://www.instructables.com/id/DIY-Wind-Turbine-2/
Step 3: Blades
Another vital part is the blades. I cut mine from 6 inch PVC pipe with a jig saw and table saw.

Cut a 2 ft length of pipe, split it in thirds, and then cut the shape from each third. The jigsaw was used to rough cut the shape, and the table saw to straighten them. My
cuts were less than perfect, so I had to sand them down for even weight and size.

http://www.instructables.com/id/DIY-Wind-Turbine-2/
Step 4: Backbone
There will need to be a backbone to connect the motor to the tail and the stand. Mine already had a section of square iron attached.

At this time, add the tail and find the balancing point. The balancing point will be where it attaches to the stand.

Drill, tap, and install the pipe flange.

Image Notes
1. Mark where it balances at.

http://www.instructables.com/id/DIY-Wind-Turbine-2/
Step 5: Flywheel
To prepare the flywheel to accept the blades, you will need to drill and tap holes in 3 spots. I used 1/4"-20 thread machine screw for my blades.

Drill and tap the first, measure 120 degrees around, and repeat. You should now have 3 holes evenly spaced across the flywheel.

Drill 2 holes in each blade.

Screw the blades into the 3 holes you just drilled and tapped on the flywheel.

You should currently have the blades screwed on with only one screw, so that they can pivot. Measure the distance between the tips of each blade. Once they are all
even, mark your 3 additional holes on the flywheel, making your marks through the second hole you drilled in each blade. Drill and tap at each mark, and screw your
blades on with an additional screw.

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Step 6: Assemble
Paint the parts. Assemble everything together and take it for a test drive. I wanted all the bugs worked out before it was in the air, so I strapped it onto a trailer and took it
for a whirl.

For the turbine to be most effective, the blades and flywheel should all be in balance. To be sure it's well balanced, spin the blades several times, marking whichever side
ends up on bottom. The marks should all be spread around randomly. If they are all in one spot, you need to lighten that side by sanding or drilling away some material.

http://www.instructables.com/id/DIY-Wind-Turbine-2/
Step 7: Wiring
The test drive and balance tests were a success, so it was time to wire everything together.

The negative wire from the inverter and from the turbine both connect directly to the negative battery terminal. The positive from the inverter connects to the battery with a
fuse in line. Connect the positive wire from the wind turbine through a diode and a fuse.

The turbine can be mounted on a portable stand (as pictured) and held with guy lines, or mounted to a permanent structure. I plan to permanently install mine on a
marker post at the corner of the property.

Thanks for reading. If you have any questions please post them below, I will be glad to answer them.

Image Notes
1. inverter attached to battery box with wiring enclosed inside

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 Related Instructables

How to- Wind How I built an Wind Turbine/s How to Build a Solar And Wind
Turbine Made electricity For Free! (Small Wind Power Energy Facility
from Scrap Power Tower producing wind 8"inch Blades) Generator by Team Power
Metal... by (plans) - turbine by by u971 (video) by
Pushthatbolder electricity mdavis19 doctorgig
generation from
solar, wind and
water in one
device (Photos)
by matt392

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Comments
5 comments Add Comment

3366carlos says: Sep 27, 2014. 11:36 AM REPLY

wow!

chrisdav says: Sep 27, 2014. 11:08 AM REPLY

I would have a switch that can short out the generator and disconnect the battery at the same time.

chrisdav says: Sep 27, 2014. 11:06 AM REPLY

Hi
I created a wind turbine very similar to yours with a treadmill motor and pvc as blades. I also built a dc-dc step up buck circuit, the whole thing worked well for
a while until we had a gale force wind, it was spinning so quickly that one of the blades shattered and went straight through an asbestos roof! So please be
careful if you are in an area that has gale force winds

petercd says: Sep 27, 2014. 10:02 AM REPLY

Great instructable, I don't see a charge controller anywhere in your setup, the mdavis19 one works a charm and its what I use in my setup.

MsSweetSatisfaction says: Sep 27, 2014. 9:11 AM REPLY

Woah it didn't even occur to me that we could DIY something like that. Awesome job, now it seems very silly that resistance to wind turbines in the
government if we can DIY it at home... Thanks for sharing, and again nice job!

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