How to Build a Small Scale Wind Turbine from Scrap Parts to Cut Your Energy Bill

Introduction

With energy prices constantly rising, many homeowners are looking for ways to cut their electricity bills. One great option is to build your own small scale wind turbine from recycled and scrap parts. Constructing a DIY turbine is an affordable and fulfilling project that allows you to generate clean, renewable energy and reduce your reliance on the grid.

In this comprehensive guide, I will walk you through the entire process of building a scrap parts wind turbine from start to finish. I’ll cover selecting optimal materials, critical design considerations, turbine assembly, installation, and maintenance. Follow along to learn how I built my own functional turbine on a budget using mostly salvaged components.

Selecting Materials from Scrap Parts

The first step is sourcing secondhand or salvaged materials to build the turbine. With some creativity and hunting around at scrapyards and garage sales, you can find most of what you’ll need either very cheaply or for free. Here are the key components I used for my scrap parts turbine:

Rotor Blades

• PVC pipes - I used 3 inch diameter PVC pipes cut into 1.5 foot segments to form the rotor blades. Make sure the lengths are equal so the blades are balanced.

• Scrap wood - For added support, I cut scrap 2x4 lumber into strips and attached them lengthwise onto the PVC pipes with glue and screws.

Hub

• A rounded wooden table leg works perfectly as a hub to attach the blades to. Make sure the diameter fits inside the PVC pipes.

Generator

• Old computer brushless fan - The rotor from a brushless computer cooling fan acts as the generator. Check that it spins freely.

• Scrap metal - I used leftover sheet metal to fashion a mounting to connect the fan rotor to the wooden hub.

Tail

• Metal fencing - I cut a long diamond shape from some old metal fencing to make the turbine tail. This stabilizes it.

• Scrap wood - Additional wood pieces reinforce the tail structure.

Tower

• Metal pole - I found a long sturdy metal pole on craigslist that serves as the tower to mount the turbine on. Use at least 10 feet.

• Concrete - The base needs to be set in concrete to keep it stable. You can often find leftover bags of concrete mix for free or cheap.

Wiring

• Old extension cord - An extension cord provides the necessary wiring to connect the generator to your home and power battery bank.

Design Considerations

Carefully planning out your wind turbine design is crucial to maximizing power generation. Keep these key factors in mind:

Blade Number & Length

• The longer the blades, the more wind energy can be captured. Make them as long as your materials allow, up to around 5 feet.

• 3 blades is optimal for DIY designs. More blades would add complexity.

Generator Output

• Choose a computer fan that can generate 400 watts or more so it has enough power capacity.

• Consider looking for an industrial quality brushless DC motor if you have access to one. This will handle more energy.

Tower Height

• Mount your turbine on the highest tower feasible, at least 10 feet tall or more.

• Higher towers capture faster, unobstructed wind to increase energy production.

Turbine Direction

• Place the turbine perpendicular to the prevailing wind direction in your area to maximize exposure.

• Add a tail fin to automatically orient the blades into the wind.

Assembling the Turbine

Once you’ve collected materials and planned the design, it’s time to start building. Follow these steps to assemble your scrap parts turbine:

1. Cut rotor blades to equal size

• Measure and cut your PVC pipes to the desired blade length (1.5 feet for my design) using a handsaw.

• Cut strips of scrap wood to attach and reinforce the PVC pipe blades.

2. Attach blades to hub

• Drill holes through the ends of the PVC blades to align with the wooden table leg hub.

• Secure the ends of the blades evenly spaced around the hub using bolts, washers and nuts.

3. Add generator mount

• Use sheet metal to fashion a mounting bracket for the brushless fan generator.

• Attach it to the hub using screws so the rotor axle lines up in the center.

4. Build tail structure

• Cut a diamond shape fin from fencing and reinforce with wood.

• Attach it to the generator mount so it can pivot to direct the turbine.

5. Test spin

• Check that the blades spin freely without wobbling.

• Verify the tail aligns the turbine properly.

• Spin manually to test the generator output with a multimeter.

Your scrap parts wind turbine is ready for installation!

Installing the Turbine

Proper installation is key to maximizing power generation once your turbine is built:

1. Erect tower

• Dig a 2 foot deep hole and fill with 6 inches of gravel for drainage.

• Place the metal tower pole centered in the hole and fill with concrete to set. Make sure it's completely vertical.

• Allow the concrete to fully cure before mounting the turbine (usually about 3 days).

2. Mount turbine near top

• Attach the assembled turbine near the top of the tower pole, but not at the very top.

• Use sturdy metal brackets to bolt it into place.

3. Wire to battery bank

• Run wiring from the turbine generator down to a sealed battery bank to store the energy.

• Use an Automatic Charge Controller to regulate the power going to the batteries.

• Connect an inverter to the battery bank to convert DC to AC for powering devices.

4. Ground the system

• Ground the wind turbine, batteries and any conduits to protect from lightning strikes.

• Use thick gauge copper wire and grounding rods.

Proper grounding is extremely important for safety and preventing damage to electronics.

Performing Regular Maintenance

Like any mechanical system, your DIY turbine will require periodic maintenance to keep it running efficiently:

• Check electrical connections for corrosion and tightness. Loose wiring can cause power loss.

• Verify bolts and blades are secure so vibrations don't loosen components.

• Clean debris and dirt buildup on blades to maximize rotation.

• Lubricate the generator bearings annually.

• Inspect for any cracks or damage, especially on the blades or hub. Replace components as needed.

• Check cable integrity on the tower. Replace any worn sections.

• Tighten and adjust guy wires attached to the tower to keep it oriented properly.

Performing preventative maintenance will extend the turbine lifetime and productivity.

Conclusion

Building a small wind turbine from scrap parts is a great DIY project that allows you to generate your own renewable energy. Follow the steps I outlined for selecting used materials, designing efficiently, constructing the components, installing professionally, and maintaining regularly. With some persistence and ingenuity, you can build an effective scrap parts turbine that will slash your electricity bills for years to come. The ability to harness clean wind power is incredibly rewarding.

Let me know if you have any other questions! I'm happy to provide more details on any aspect of how I successfully built my own functional wind turbine on a budget.