Introduction: 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.
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.
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.
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61 Comments
Question 5 months ago on Step 3
I have to construct wind turbine blades for a school project. is there any reason you chose the particular size and shape?
Tip 11 months ago
Use ur phone to video & audio recorder what & how u r doing each part of the diy build process, so that if it doesn't function properly when you complete it...., U will be able to go back & review what & how u preformed each step of the process, which will enable u to visualize exactly what & where u went wrong.... Allowing u to quickly pin-point the problem & fix it, instead of wasting hrs just trying to find the problem, not to mention the time it will take u to fix/adjust it!
Question 11 months ago on Step 7
Why don't you provide a simple short video, that captures at least the main/most-important points, and/or the parts of the process which gave you the most difficulty/problems you needed to overcome (& how u overcame them); since there's a great chance that most of us (your readers/followers), will also experience such issues during the process while following your instructions and making our own Diy Wind Turbine Generator from an old DC Treadmill Motor???
2 years ago
dose any one know where i can find a full DIY build potable wind turbine?
so far the only ones i have found are ether too big or too heavy to be mounted on a RV.
Question 3 years ago
How quickly does this charge the battery? what is the voltage output? how many amps?
8 years ago
Won't the wires tangle if the thing turns toward the wind all the time? Just curious as how that is to be handled.
Reply 6 years ago
I built one of these myself. I put the wires in the pipe. They do not get tangled up like you think.
Reply 8 years ago
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
Reply 6 years ago
And this is the very reason you don't need to worry with slip rings. The chance that the wire would twist enough to snap is near zero.
Reply 8 years ago
I would install a swivel connection inline on the wiring. While it won't spin constantly around the post, it will eventually twist your main cable until it breaks. Otherwise, great Instructable.
Reply 8 years ago on Introduction
Easy-Peasy, as some kids say; either use slip rings (better), or rotation-limiting hardware and a wire leads loop.
7 years ago
I like what you did here and this is one of the best explanations I have seen! Nice!
We have a mini version that is more of a model for the classroom.
https://www.instructables.com/id/Wind-Turbine-Model-1/
Reply 6 years ago
great job, that's really neat. I might have to build a mini turbine too
7 years ago on Introduction
hello there !, a bring a question from santiago de Chile.
about the wire, how do you deal whit the full rotation of the wind turbine whitout tearoff the cables from?
ps: nice work by the way
Reply 7 years ago on Introduction
I suspect you have found out already by now, but you can use a 'capsule slip ring' which allows the current to flow through it without twisting the wires.
https://www.instructables.com/id/Wind-turbine-mount-using-old-office-chair/
7 years ago on Introduction
is a great indestructible for a wind turbine
8 years ago on Introduction
Very cool instructible. Do you not run the risk of overcharging the battery without some sort of shutoff though?
8 years ago on Introduction
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...
Reply 8 years ago on Introduction
I wonder if you could make your attic wind tunnel out of a length of PVC running from one end to the other, using computer fans inside as the generators. Those things move fairly easily and you can probably get an endless supply of them for free.
Reply 8 years ago on Introduction
The inefficiency of such a contraption would cause it to generate so little power as not to give payback in its service life time.