THE FORUM IS NOW AT buildyourownwindturbine.com

coils wired up with starts and ends outside


this is the stator for the 3.6 m machine ,coils have 80 turns 1.7 this time and came out a little on the fat side, not much clearance on narrow parts of the mould or between coils but fitted ok (thicker wire and my winding probabely)

after waxing (floor wax) and placing in the fiberglass cloth i slid in coils in the wrong place and had to move them in the mould ,not a good idea as the cloth moved too leaving bubbles underneath , plenty of teeth gnashing at this point , the little fiberglass tabs on the coils helped keep things in the right shape though

24 hours later opened her up and convinced the stator to come out at gun point ,it was tight (probabely not enough wax around the island and rim) came out in the end ok, the back and lid didnt stick at all

next up is the frame and rotors ,
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the blade hub is for fibreglass props but will be binned as its a mixture of welded cast and mild steel using ordinary rods
this little adventure in welding is probabely an accident waiting to happen
i came across a small engineering shop run by a helpfull man (paddy) who machined up the rotors
from 12mm plate , had a few alignment problems (should have left the hub with him) half an hour with a good file and everything
fitted together ,paddy reconed they were a bit tricker than he first thought (big diameter on a lathe) at the start he recommended
lathing down the plates so i just went along


the frame is to the same specs as gryeum but using as much as possible of the stuff i have lying around
nice and rusty too
next to get some resin ,the magnets are epoxy coated so i might spoil meself with epoxy resin buts its expensive
grs in cork sell an epoxy (3kg) for 62.00 plus vat ,

looks good Niall,
is that shrink wrap on the leads out,
what output are you aiming for
where do you get your blades
I have my 10 ft almost ready to go, need to get cable
rectiifer and decide what to do with all that power, water heating maybe
windspeed

it is shrink wrap , i should have been more carefull sliding in the coils to the wire exit points , pics dont should it but there are a few nice bubbles in there its wired for 48v with an option of trying at 24v in delta (earlyish stall but a possibility),it,ll never be driven that hard anyway where i live
but the rest (batts invertor etc wont come till later (much later) , blades i dont really know about yet ,the alt is hughs design for the 3.6 m machine laminated carved blades would be an cost effective option ,if i stray too much on choice and diameter theyl mismatch the alt , i have a set of fiberglass ebay blades which might do just to get it running , i was thinking about some water heating too , it might suit me and allow smaller capacity batts ,i have few second hand 85ah sla batts which i need to use


your 10ft sounds interesting did you base it on anything ?

I would stick to hughs diameter
I wonder if one could shorten blades to suit
I just finished my 10 ft blades made them from selected 9" x 2" softwood ceiling joists didnt want to ruin anything expensive first time, and it was free,took nearly two days to carve, had to remake one because of a knot in the wrong place, but I got them tidied up and varnished ,they look fine on the bench nice and light
My turbine is based on the Dans at other power.com which I think is based on hughs plans
windspeed