How to Make Miniature Wind Turbines

The Blade Assembly

• 1

  Measure and quarter a 24-inch length of 6-inch diameter PVC pipe lengthwise. Mark a spot 2 inches from the edge on one of the pieces, then measure 20 inches along the length, drawing a line around the pipe -- also make a mark 2 inches along the line. Cut a diagonal line between the two points.

• 2

  Measure 2 inches around the pipe at the end beyond the diagonal cut, and join to the 2-inch mark you made on the line. Cut the rectangle left by the marks to leave a blade shape and sand the edges. Repeat for the other the quarters of pipe to make the wind turbine blades.

• 3

  Mark the center of an aluminum disc, 6 inches in diameter and 3/8-inch thick. Drill a hole at this point that’s the same diameter as the shaft on the motor. Lay the blades on the disc so their shafts are equidistant from each other. Drill two holes through each shaft and through the disc and bolt the blades in place. Fit the blade assembly on the motor shaft and secure in place with a clamp.

• 4

  Cut a 24-inch length of two-by-four lumber. Attach the motor and blade assemble at one end -- use metal straps and screws to secure to the wood. Cut a piece of heavy aluminum 12 by 12 inches. At the center of the other end of the wood to the motor, cut a groove 12 inches long and 1 inch deep. Slide the aluminum in place to make the tail and glue to secure it.

• 5

  Screw an end fitting for the 1-inch steel pipe to the underside of the lumber at the wood’s midpoint. Screw a 12-inch length if 1-inch steel pipe to this and attach a hose clamp around the pipe 3 inches in from the other end. Drill a hole through to wood to the pipe.

Assembling The Wind Turbine

• 6

  Use 1 1/4-inch metal conduit for the mast of the wind turbine. Drill a hole 15 inches from the bottom of the conduit and run electrical wire through to the top, then through the pipe of the blade assembly. Connect the wires to the motor.

• 7

  Dig a hole and put the bottom 12 inches of the conduit in the ground, then pack the earth around it. Rest the blade assembly on top of the conduit, so the hose clamp rests on the conduit and the assembly can turn with the wind.

• 8

  Connect the free end of the wires to the controller, then connect that to the battery, which stores the electricity produced. Connect to the battery to the AC inverter to use the energy in appliances.