You need: MDF board
Assortment of gear sizes
Step 1: Support Disks.
First of all, mark a centre point on your MDF board. Use a compass to draw a circle with a radius of 160mm. Using a band saw, cut the circle out and use a sander to smooth the edges. Trace around the circle and use it to produce another disk of the same size.
Find the centre point of these circles and use it to draw a 5 pointed star on each one. These lines will be used to align the turbine blades further on in the project. Halfway down each line, mark a point and then measure a point 5mm to the right of the line and mark a cross. This is Glue or pin a square onto the centre of each disk to add support to where the axle will be sitting. Finally drill a 9mm hole through both parts.
At the end of this step you should have 2x MDF circles split into 5 segments.
Step 2: Turbine Stand.
Using whats left of your MDF board, draw a right angled triangle big enough so that when your turbine is assembled, there is enough clearance for the turbine to spin. Use this to draw another triangle of the same size. Cut both triangles out with the bandsaw. To make your turbine more aesthetically pleasing, use the sander to curve one corner of the triangle into a circle. Drill a hole big enough for your support bracket through the curved corner.
Step 3: Turbine Blades.
Attach another plastic rectangle down the other side to form a triangle and glue the 2 plastic edges together using dichloromethane . Repeat this for the other 5 pieces of thick dowel.
Step 4: Axle.
If you have a press available use it to press-fit a 4mm diameter 30mm long steel rod 15mm deep into the drilled hole on the aluminium.
Step 5: Gearing.
To solve this problem we designed a gear on illustrator that would work with the rest of the pack we were using but would give us a bigger ratio. We laser cut this part from 5mm thick acrylic plastic. The standard gears are in red and our laser cut gear is in white. After getting the white gear laser cut we drilled a hole through it and glued one of the small gears in from the standard pack so we would have a method of fastening it to the axle.
Attach the smaller gear to the motor.
Step 6: Support Bracket.
If you don't have access to a metal lathe, you can just drill partly through your turbine stand and then glue them into place.
Step 7: Assembly.
2. You should now have an almost 'bird-cage' like contraption, with all the blades pointing inwards. Slide the turbine with axle into the support brackets on the turbine stand.
3. Make a base out of a solid piece of MDF. Nail your two turbine stands to this base making sure they are very secure (this part is important because the turbine can generate enough lift at full speed to lift the front up slightly).
4. At this point you should have your actual turbine assembled and connected to your base.
5. Attach the biggest gear to the protruding piece of axle and use grub screws to secure it in place.
Step 8: Finishing Touches.
1. UPOL the dowel and plastic where they join like in the picture. Let this dry and when it has, put masking tape over it.
2. Put masking tape along the edges where the plastic meets.
3. Drill a hole through the stand big enough to house the motor. Make sure this is secure.
4. Align the small gear on the motor with the big gear on the axle.