How to Build a Small-Scale Wind Turbine Using Scrap Materials

Building a small-scale wind turbine from scrap materials can be a fun and rewarding project. With some creativity and elbow grease, I can make my own renewable energy source using discarded or recycled items. Here is a step-by-step guide on how I built my own small wind turbine using scrap materials.

Gathering the Necessary Materials

The first step is sourcing the components I will need to build the wind turbine. Here are the main items I gathered:

• Alternator - This converts the rotational energy into electricity. I salvaged a car alternator from a junkyard. Make sure to get the voltage regulator as well.
• Blades - I cut these out of an old aluminum sheet metal sign. 3 blades is optimal. They need to be lightweight.
• Hub - This attaches the blades to the alternator shaft. I used a thick steel disk and welded the blades onto it.
• Tail - This keeps the turbine facing into the wind. I used a sheet metal fin bolted onto a pivot.
• Frame - This houses the components. I welded scrap steel tubing into a tower with a swiveling head.
• Bearings - Allow smooth rotation. I used old roller blade wheels.
• Wires, bolts, nuts, tools - Assorted electrical wiring, hardware and tools.

Searching auto wrecker yards, metal recycling centers, junkyards and hardware stores helped me locate used and discounted materials.

Constructing the Wind Turbine Frame

The frame holds all the components in place as they rotate. Here are the steps I took to construct it:

• Cut the steel tubing into appropriate lengths using a hacksaw and miter.
• Layout and measure the tubing pieces and use a welder to connect them into a sturdy tower frame.
• Include a swivel bracket near the top to allow the head to self-align with the wind.
• Bolt the alternator mount and tail pivot onto the head bracket. Allow space for blade clearance.
• Attach the frame feet and reinforce all joints. Use gussets and fillets when welding.

I made sure the height puts the blades well above any nearby obstructions. The frame needs to be super rigid to handle the forces.

Assembling the Rotating Components

With the frame complete, I assembled the parts that spin:

• Press fit the alternator onto the shaft extension piece using a pipe over the shaft for leverage.
• Add the bearings onto the alternator shaft on either side of the mount.
• Bolt the alternator mount onto the swivel bracket. Make sure it rotates freely about the vertical axis.
• Position the tail fin and secure the pivot end onto the swivel bracket as well.
• Center the hub piece on the alternator shaft and tighten down the bolts.
• Attach the 3 blades equidistant around the hub and tighten their bolts. Each blade should be angled similarly.

It is important to align all the rotating parts well or it will cause dangerous vibrations.

Adding the Electrical Components

To produce useable electricity, I still needed to connect and configure the electrical conversion system:

• Attach a 12V battery to store power. A deep cycle marine battery is a good choice.
• Connect the battery to the alternator using heavy gauge wire. Use a breaker between them for safety.
• The voltage regulator modulates the output. Attach it to the alternator wiring.
• To monitor performance, wire in a volt meter across the battery terminals.
• Install a blocking diode to prevent reverse current flow at low speeds.
• Finally, attach an inverter to convert the battery output to 120V AC. Make sure it is sized appropriately.

I used a charge controller to regulate the power sent to an auxiliary battery bank for household use.

Final Assembly and Placement

After fully constructing the wind turbine, it was ready for installation:

• Do final bolting of all loose joints and do component tests.
• Hoist the entire unit with appropriate lifting equipment and move into position.
• Anchor the frame feet securely into the ground on a high, exposed site.
• Ensure guy wires are used if there is any turbulence or vibration after startup.
• Check that the blades spin freely and the tail aligns it perpendicular to the wind.
• Connect to the battery bank through a buried electrical cable.

Proper placement is crucial. I mounted mine well clear of obstructions upwind that could cause turbulence.

With care and patience, building a small wind turbine from scrap can be a fun DIY project. Just be sure to follow electrical safety codes and manufacturing principles throughout the process. With some windy weather, I am now generating free, renewable electricity!