Step 1: Marking the Pipe
I first used a length of angle iron to mark a line along the pipe, by using angle iron you get a perfect line and all your lines will be parallel.
Once the first line was marked i measured the circumference of the pipe and devide it by 3 to give the spacing for the other lines. I marked the distance on the back of the tape measure so i could wrap the tape around the pipe for a more accurate mark.
Once you have the equal distances marked use the angle to mark a lines.
Step 2: Cutting
I used a jigsaw to make split the pipe into the 3 segments. each segment would make 2 blades so i would have 6 blades from this pipe.
Once the first cut is made rotate the pipe and clamp again, after the second cut a segment will be removed from the pipe. The pie then was able to be pushed down onto the lathe bead where it sat nice and steady for the final cut.
Step 3: Marking and Cutting the Segments.
I was able to use the bandsaw for cutting the segments.
Step 4: Sanding and Finishing.
I sanded the blades on the sanding table and removes any fine burs with wire wool to give a smooth edges.
Step 5: The Rotor.
I marked the holes on each arm 75mm center to center and drilled with a 6mm drill bit.
Step 6: The Bearings.
To remove the bearing case from the tub I used a angle grinder to cut into the segments on the base of the tub, I also did the same on the inside of the tub too.
I then used a a hand axe to hack out the bearing case but not totally destroy the tub, I plan to use the remainder of the tub to make some kind of planter.
Step 7: Attach the Blades and Add the Bearing Cage.
Once all 3 blades where attached I lined up the first blade and drilled the hole for the second bolt. i then used the the tape measure to make sure the tips of the blades where at equal distances. Once all the blades where set i drilled the rest of the holes and bolted the blades on to the rotor.
I was now able to test the rotor to see if the blades worked. They worked very well, so well that I decided It would be much safer mounted on a test stand than me just holding the bearing casing.
The blades will need some sanding here and there to make them perfectly balanced, I will do this in the tweaking stage before I mount the turbine on a pole.
I hope you like my idea for a scrappy solution to the problem of making a rotor for a wind turbine.