How to Build a Wind Turbine

Build a wind turbine for around $250,

including everything but the battery!

Warning!

Power Planted LLC assumes no responsibility for the use or misuse of these instructions. Follow these instructions at your own risk. These instructions have not been evaluated by an Engineer. These instructions are intended to be "guidelines" and may be incomplete. Wind turbines can be dangerous. Use caution.

The skills required for this project are minimal. There is NO welding or machining required! Just about anyone could build this worthwhile and rewarding project.

This generator is built around an Ametek 38VDC motor since Ametek motors have become increasingly popular for use as wind generators.

Major Parts

• Generator - Ametek Motor
• Hub - Internet Purchase
• Blades - Internet Purchase
• Frame - 2x4 Lumber
• Motor Mounts - U-bolts
• Tail - Steel Sheet Metal
• Pivot - Pipe and Floor Flange
• Tower - Electrical Conduit
• Guy wires - Wire or rope
• Charge Controller
• Battery
• Electrical Wire

Tools Required

• Adjustable wrench or socket with
  ratchet to fit nuts on u-bolt
• Screwdriver
• Drill with a 1/2" and 3/16" drill
  bit
• Saw

Parts in Detail

• Generator

  This generator uses an Ametek 38VDC motor.
  The operating voltage for different Ametek
  motors varies but any motor rated for 30VDC
  or more should be fine. There are a number
  of people and businesses selling Ametek
  motors both new and used. Ebay is an easy
  place to find an Ametek Motor. It should
  be noted that any DC motor with similar
  specifications to those of an Ametek can
  be used. Because of popularity, hubs are
  available for Ametek motors that make the
  build easy.













• Hub

  The hub is what ultimately connects the
  blades to shaft of the generator motor.
  This turbine uses a hub specially made for
  this purpose. Like motors, hubs can also
  be found by a number of people. This hub
  was purchased at Wind Stuff Now. Hubs
  are available at Wind Power Generations
  and Ebay as well.
















• Blades

  There are several ways to get blades.
  There are many sites that illustrate how
  to make blades for those interested. We
  chose to purchase blades for safety reasons.
  Wind Power Generations sells Air-X type
  blades, which is where these blades came
  from. Blades are also available on Ebay.

















• Frame

  The frame holds everything together and
  needs to be sturdy. It does not need to be
  complicated. The frame for this turbine is
  a 2x4 piece of lumber! 2x4's usually come
  8' long. Most hardware stores can cut the
  2x4 for you so this project can be completed
  without the use of a saw. The 2x4 should be
  cut to 4'. It is not at all critical to get
  this measurement exact.















• Motor Mounts

  We are calling them motor mounts, but they
  are just U-bolts with plates across the
  legs. The U-bolts secure the generator
  motor to the 2x4 frame. The U-bolts need to
  be big enough to go over the motor and long
  enough to hold the motor to the 2x4. We
  slid flexible tubing over the bolts where
  they come into contact with the motor.
















• Tail

  The tail is made from steel sheet metal.
  The piece came the perfect size and required
  nothing more than drilling holes to attach
  it to the 2x4 frame. The sheet metal that
  we used required paint because it was bare
  metal. You should paint the bare metal tail
  or use galvanized steel or aluminum.

















• Pivot

  The pivot allows your wind turbine to spin
  around on top of the tower. When allowed to
  spin, the tail will always keep it aligned
  properly whichever way the wind is blowing.
  The pivot is made by sliding one length of
  pipe into another. A base mount is secured
  to the wind turbine's 2x4 frame. A threaded
  length of pipe is screwed into the base
  mount. This is then greased before sliding
  it into the tower pole. The tower itself is
  the other pipe that makes up the pivot.













• Tower

  The tower holds the completed wind turbine
  up so that it can catch wind and spin safely
  above the heads of people on the ground. The
  turbine tower is made from heavy wall
  electrical conduit. This is suitable for a
  low tower (under 12 feet).


















• Guy Wires

  The guy wires are what keep the pole secure to
  the ground. Chain link fence pipe clamp
  parts are used to attach guy wires. The
  particulars of the wires are not important,
  just be sure that they are capable of
  keeping the tower in place in high winds.
  Also be sure that the material you use for
  the wires will not stretch.
  
  
  
  
  
  
  
  
  
  
  
  
  
  

• Charge Controller

  The completed turbine will need a controller
  to regulate the charging and dumping of wind
  power. The perfect way to control any kind of
  home built generator is to use our charge
  controller. It will connect charging power to
  your battery until it is full, then switch the
  power to a diversion load until the battery
  needs charging again. Since the controller
  automatically switches power to a diversion
  load, it will take care of keeping a load on
  the wind turbine to prevent it from
  overspeeding. The charge controller also
  includes the instructions for making all of
  the wiring connections.










• Batteries

  With the generator up and running you will
  need a place to store the power that you
  produce until you are ready to use it.
  Deep cycle batteries and golf cart batteries
  work the best. Many other types of batteries
  like UPS (battery back-up) batteries can be
  used as well.
  













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