To recreate the ECO Chic Windmill just follow these easy straight forward steps.
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Step 1: What You Need.
To recreate the ECO Chic Windmill you need:
1 sheet of 6mm thick acrylic 250mm x 500mm
Aluminium rod 500mm length x 8mm diameter
500mm x 500mm x 10mm MDF
4 x Bearings
Set of Bevel Gears
Step 2: Create a Mould
Create a mould by forming wood into your desired shape.
Then cut it in half to provide space for the axle.
Step 3: Produce Casts From the Mould
Cut your acrylic in half length ways and place it on to a pre prepared vacuum former place your mould in the centre and create the cast.
Repeat this for the other half of the acrylic also.
Once you have your casts cut them out around the edges to produce your fins.
Step 4: Creating the Main Axle
Take your axle and reduce the diameter at both ends to 6mm to fit the bearings.
At one end make it 10mm deep and the other 40mm to accommodate the gears and bearings to be attached at a later date.
Step 5: Create the Stand
To create the stand produce two end parts at least 200mm tall to hold the axle.
Produce this with MDF and counter sink a space for the two bearings.
Then create a stand to mount the motor make the motor sit at a 45 degree angle from you base board like the one below.
Step 6: Adding It All Together.
First start with the end of the axle that was filled 10mm
Attach the bearing
Then using hot glue attach the first wing of the wind mill at least 5mm from the bearing
Then attach the second wing at a 90 degree angle from the first.
Using one of the two stands created earlier insert the bearing and attach the stand the the base board using two screws careful not to split the wood.
Now back to the axle and attach the other bearing and stand and attach to the board.
Step 7: Adding It Together Part 2
Next insert your motor into its stand and attach the second part of the bevel gear onto it.
Now line up your motors gear with the gear on the axle and give it a go at turning if it doesn't do this frictionlessly have another go if it works perfectly glue it down quickly with hot glue. (it can take many attempts to get it good so when you get it you don't want to lose it!)
After this screw the motor down and just double check it works.
Step 8: CONGRATULATIONS YOUVE COMPLETED IT!
Well done after this its yours to do what you please. You can decorate it if you want.