How to Build a Windmill Generator the Best Way

Build your own windmill generator at home.

You can build a windmill generator at home and start cutting back your electrical bills. Using available blueprints for windmill generators you can build a renewable green energy system by yourself. Ben Ford's ebooks on homemade energy available at his website give detailed instructions and plans for wind and solar systems to power you home. Build your own generator system at home using common tools. Many of the materials you will need can be found and used to save you even more money.

Things You'll Need

• Schematic or blueprint for windmill generator
• 3-foot length of 8-to-12-inch ABS or PVC pipe
• Jig or table saw
• Grinder
• Sandpaper
• Paint or UV protective coating
• Drill
• Steel hub
• Assorted nut and bolts
• 3 steel bars, 2-by-12 inches
• DC motor
• Charge controller
• Battery bank
• AC inverter
• Wiring
• Soldering iron
• Socket wrench set
• Screwdriver set

Instructions

Assemble the Windmill

1. Cut 8-to-12-inch PVC pipe lengthwise into four parts using the table saw. Shape each part identically according to the directions of your blueprint.

2. Grind and sand the edges of each plastic blade so they are aerodynamic and smooth. The trailing edge of each blade should be ground at a sharp angle to reduce wind friction.

3. Attach three blades to a steel hub using bolts and steel bars, which will add stability and strength to the blade assembly. A detailed template for making your own hub is featured in the book "Home Made Energy."

4. Place the blade assembly on a horizontal pole by its center hole and number each blade with a marker. Spin the blade assembly and observe which blade finishes on the bottom. Repeat this test 10 times, if one blade finishes in the down position more than the others, it is probably heavier than the two others. Balance it by shaving off part of the steel connecting bar to reduce weight.

Assembling the Electrical System

1. Build the windmill base with a DC motor according to your blueprint and bolt the blade assembly to the motor axle.

2. Wire the DC motor to a charge controller using a soldering iron or bolts. A 45-amp charge controller will work best. Set the charge controller to turn the current on and off when the battery charge exceeds or dips below a specific voltage -- 11.7 volts and 14.3 volts work best for these levels.

3. Wire the charge controller to a bank of "deep cycle" batteries using a soldering iron or bolts. Deep-cycle batteries are used in golf carts and fork lifts. Facilities that use these vehicles might let you take away their used batteries for free. Many batteries that are presumed "dead" can be refurbished using a desulfator. The number of batteries you will need depends on your power needs. The "Home Made Energy" manual provides suggestions for the number of batteries needed for your power output.

4. Connect your battery bank to an AC inverter by soldering or bolting. The inverter converts the DC battery energy into alternating current used in homes. Now you're ready to plug in common home appliances.

Tips & Warnings

• Keep the leftover fourth piece from the PVC pipe. It can be made into a spare blade if one breaks or you make a mistake while shaping.

• Use a UV coating or paint on the plastic windmill blades to prevent sunlight from degrading the plastic over time.

• Many of the necessary parts such as deep cycle batteries, the charge controller, AC inverter and DC motor can be used.

• For optimal results, use a DC motor with high voltage and low rpm. A motor between 30 and 90 volts that operates below 425 rpm at 12 volts.

• If you build the battery bank and inverter system outdoors, you will need to house them for protection from the elements.

• How much wire to use between components and the gauge of the wiring you should use will depend on your location, materials and power needs.

• If the windmill blade assembly is unbalanced, it will lose some energy-collecting efficiency and eventually damage the motor.

• Batteries can be explosively dangerous. If you have any doubts about your system, consult a professional.

References

• "Home Made Energy"; Ben Ford; 2008
• "DIY Wind Turbines"; Ben Ford; 2008
• "No Cost and Low Cost Energy Saving Tips for Your Home"; Ben Ford; 2008

Resources

• Home Made Energy