This was just a little science experiment I always wanted to try. Hope you find it helpful and enjoyable

Step 1: Materials and Tools

Materials
1/2" aluminum rod
3/4" copper coupler
Electrical tape
6"-1/2" pex(optional)
#12 wire
2 rubberbands
2 3/4-2" bearings
2-2" nipples
2' unistrut
Battery or power supply
2'-2x6

Generator/windmill
Some type of fan blade
I took mine off of an old condenser fan

Step 2: Construction

I don't Take any pics from when I was constructing the frame but the whole idea came from scrap. You will basically want something to hold the shaft(rotor) and the magnets(stator). I used some 2 inch nipples to hold my bearings and some bent sheet metal to hold my magnets. Also added the top brace to hold my brushes. Which also helped brace my stator.
For my windings I used some #24 magnet wire

I drilled out my shaft and put in a piece of six inch threaded rod
Next, secure one coupling on an insulator on the shaft. I brazed the wire to the coupling. Then started wrapping wire 400 turns. In the same direction switch to the other side. Make ale the same number wraps.
All this should be insulated from the shaft. If it ain't, it won't work. Trust me. I didn't pay attention after I brazed the commutator the first time. Went to ohm it out and had to unwrap 400 turns.

Braze the next coupling. These are now commutators.
Mount to your housing.
Next you will need magnets parrallel with your windings. I used som sheet metal and used a coat hanger for much needed bracing.
Finish your commutator by insulating the top half on one side and bottom half on the other. This was tricky and made me realize that my next motor will be brushless.
On to the current one. Lol
For the brushes I took some #12 wire and did some twisting and maneuvering around the rubberbands. I have a hard time explaining so try and study the pics.
For the magnets make sure that all of them are pointed in the same direction, N/S. Don't guess on this.

Step 3: Running and Gunning

http://youtu.be/pnBaEosgElM

This is the test run at 18 volts and 12 volts. Later I did some twerking to the commutators and stepped it up to twenty four volts and it ran awesome.
I'll post more videos. Good luck and let me know if I've left any gaping holes in anything