Its time to blow some Air here and there.....
The convince offered by cordless tools is just awesome and nowadays cordless tools are getting more and more powerful.
Well, In this instructable I am going to built a powerful Air blower that is powered by my cordless tools battery. The idea behind this project is to built a powerful yet cheap air blower out of very common hardware lying around. As all my tool lineup is from AEG 18v cordless series so this pump is made to fit the standard 18v lithium batteries offered by AEG.This not only gives me the convenience of powering this air blower on the go but it also enables me to use the same battery for all my tools.
Its not necessary to use the same cordless tool battery that i have used in this instructable but you can also power it with a 12v lead acid battery.
Now lets get building !!!
Step 1: Impeller Housing
First we are going to cut down a 1.5 inch wide slice of pipe out of 4.5inch diameter UPVC pipe. This will act as the base for the impeller housing.
The pipe is cut using a miter saw to ensure a flat cut on both edges but it can also be done by using a handsaw carefully cutting through the pipe.
Step 2: Plexi Glass Plates
Both the front and rear plates of the impeller housing is made out of 5mm thick plexi glass sheet. The clear sheets not only gives the whole unit an attractive look but also provide a clear look of the inside mechanism of the air blower.
The plates are cut down using an adjustable hole saw having a cutting diameter of 5 inches. The diameter of the front and rear plates is a bit bigger than the impeller housing pipe since we are going to use some external mounting screws.
Both the plates were than sanded using a file.
Step 3: Motor Mounting
The rear plate acts as a mount for the motor.
To mount the motor on the plexiglass sheet, a pair of 4mm holes are drilled and the centre hole is widen enough to tightly fit the motor front collar in the plexi glass sheet.
The motor is then mounted using a pair of 4mm flat head screws to ensure a safe clearance between the impeller and these mounting screws.
Moreover, 6 holes are drilled near the edges of the plexi glass which will later act the mounting holes for the impeller housing.
The front plate is drilled with a hole saw to enlarge the hole so to mount the intake pipe. This intake pipe will also act as a safety feature to ensure that nobody can accidentally put finger inside the impeller housing.The intake pipe is made out os 1.5 inch UPVC pipe.
The same pipe is used to make the outlet nozzle. The end of the outlet nozzle that is going to be mounted to the impeller housing is cut down using a 4.5inch hole saw which enables us to perfectly mount the outlet nozzle to the impeller housing.
Later a hole is cut down in the impeller housing pipe for the outlet nozzle and then glued both the pieces.
Step 5: Painting the Impeller Housing
The impeller housing and the intake pipe is then painted using a matt black spray paint.
Step 6: Making the Impeller
To built the impeller I have cut down plastic sheet out of an old oil can. I have cut down two 4inches diameter plates out of this plastic can.
For mounting the impeller to the motor I have cut down an old pen and glued it to the main plate of the impeller.
The blades of the impeller is made out of 3inch UPVC pipe. First I have cut down four 20mm wide slices out of that pipe using a miter saw to ensure flat edges of the pipe which is necessary to mount the blades frimly to the impeller plates.
Step 7: Assembly
First the motor is attached to the plexi glass sheet using two flat head 4mm allen screws. A rubber fuel pipe is then placed over the motor shaft which act as an adapter between the motor shaft and the impeller. The impeller is then mounted over the rubber pipe being placed over the motor shaft. The impeller housing is then placed between the two plexi glass sheets and the whole assembly is completed by using six 4mm nut bolts across the front and rear plexi glass sheets.
Step 8: Base/Battery Adapter
I have decided to power this air blower using my cordless tools battery. Since I am using AEG cordless tools lineup that is powered by 18v lithium polymer battery so i have made a battery adapter out of plywood sheets which also serves as a base for the air blower to sit over.
The base is made such that to fit perfectly over the battery and lock in position to ensure a good grip while operation. Later the base is painted matt black.
Step 9: Motor Wiring
I have used two wire connected to the motors whose other ends are attached to the elevator clips to power the air blower. Moreover I have used a heavy duty switch to operate the blower on demand.
Both the elevator clips are attached to the battery terminals before sliding the whole assemble on the battery.
Step 10: End Results
The end results are awesome.....
Since the motor is rated for 12v applications in most cases, running this motor on 18v enabled me to get a boost in performance and the amount of air coming of the outlet nozzle is just outstanding. This small blower pumps out comparable amount of air as a corded air blower.
If you like this projects then don't forget to visit my youtube channel for the videos of different creative projects.