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DIY Dave
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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.
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.
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.
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.
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.
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.
Don't forget to vote for this instructable in the Remix contest.
We have a be nice comment policy.
Please be positive and constructive. I Made it! Add Images Make Comment
Nice easy flowing writing style! As others have mentioned a reliable means
of preventing over-speeding would be great.
Thanks for the input. I plan to use up the battery power pretty
consistently. If I find I need it, I have a spare charge controller that I
purchased with a solar panel.
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
DIY Dave (author) chrisdav 14 hours ago Reply
to the wind when you need to stop it from turning too fast.
It is
the same technique that was used on wind mill water pumps. When
the
cistern was full the pump was disabled by turning the mill parallel to
the wind. The image below shows the pump in the idle position.
The turbine puts out DC current that charges a battery. Then it flows
through an inverter that converts it to AC (regular plug in power).
The inverter has 2 standard plug ins and a usb charging port
have 4200 Watt solarpannels on my roof, next thing from mother earth to
collect is wind. Not allowed to install a windturbine where i live, so i'm
thinking of an installation that blows into a round window in my rooftop, kind
a tunnel with a mill inside.
So i would not install it outside, but inside my house.
This simple set up seems perfect to start trials...
Won't the wires tangle if the thing turns toward the wind all the time? Just
curious as how that is to be handled.
I'm planning to leave the wires fairly loose so they won't get twisted
too badly. The turbine won't make full circles often, usually just
partial rotations
this is something i would love to do.i need to learn more about wiring and
power.thanks!
having an old treadmill like this i had the idea of giving the kids something
to run for.. by connecting it up to a set of lights.. but you really had to run
hard to get the first light up - and i was told i needed a reostat? or
something? ( no electrical knowledge) to make it easy to start... does this
apply for the turbine too?
I would have a switch that can short out the generator and disconnect the
battery at the same time.
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!