How to Build Your Own Wind Turbine From Scrap Materials

Building your own wind turbine from scrap materials can be a fun and rewarding project. With some basic mechanical skills and scrap parts, you can generate clean renewable energy right at home. Here is a step-by-step guide on how to build your own wind turbine on a budget.

What You Will Need

To build a wind turbine from scrap materials, you will need the following:

• Motor - This will act as the generator. Look for a DC motor out of an old appliance like a washing machine or fan. The bigger the motor, the more energy it can generate.

• Blades - The blades capture the kinetic energy from the wind. You can repurpose sheets of plywood, plastic or metal into blades. Old table or ceiling fan blades also work well.

• PVC pipes or poles - This makes up the body and mount for the turbine. Gather scraps of 1-3" diameter PVC pipes. Metal poles, rods or conduits also work.

• Bearings - Allow the turbine to spin freely. Scavenge ball bearings from old in-line skates, fidget spinners or anything else with spinning parts.

• Charge controller - Manages the electrical load and prevents overcharging. Find one out of an old electric wheelchair, scooter or solar panel system.

• Batteries - Stores the energy generated. Small 12V batteries out of alarm systems or emergency lights will do.

• Inverter - Converts DC electricity from the batteries into AC for household use. Get one from an old UPS.

• Electrical wire and basic parts - For connecting the components. Scrap copper wire, switches and capacitors will work.

• Tools - Like a drill, saw, screws, nuts/bolts and welder if available.

Designing and Building the Turbine

Here are the basic steps to assemble your wind turbine:

Step 1 - Design the Blade Dimensions

• The blade length (L) determines how much wind power your turbine can harness. Longer blades can capture more wind.
• As a rule of thumb, a small turbine's blade length should be around 20% - 30% the rotor diameter (D). So for a rotor diameter of 8 feet, optimal blade length is around 2 feet.
• Design your blades to be lightweight yet sturdy. Thicker blades like plywood generate more torque. Thinner blades like plastic sheets spin faster.

Step 2 - Build the Rotor

• The rotor attaches the blades to the main shaft.
• Cut your materials into blades of the same dimensions. Make 2-3 blades for balance.
• Join the blades into a hub at equal 120 or 90 degree angles from each other.
• Attach the central hub securely to a rotating shaft. Try using bolt, screws or welded joints.

Step 3 - Mount to a Tower

• The turbine needs to be raised high above any nearby obstacles to reach stronger winds.
• Use PVC pipes, metal poles or rods to build a tower frame. Use guy wires to stabilize it.
• The tower height depends on the location. 10 - 15 feet should be adequate for most residential areas.
• Mount the rotor assembly atop the tower and align it perpendicular to the wind direction.

Step 4 - Add a Tail

• The turbine needs a tail to stay facing the wind.
• Make a lightweight tail from a simple plank of wood or metal sheet. Attach it off-centered on the back.
• The tail keeps the rotor steadily facing into the wind like a weathervane as wind direction changes.

Step 5 - Couple the Motor Shaft

• The rotor transfers rotation force via the shaft to spin the motor.
• Attach the motor shaft and rotor shaft in line using a mechanical coupler.
• Make sure both shafts are aligned for smooth rotation. Use shims or spacers to prevent friction.

Step 6 - Wire up the Components

• Connect the motor generator outputs to a charge controller.
• Link the charge controller to one or more batteries to store the power.
• Use an inverter to convert the battery DC output to usable AC electricity.
• Follow proper polarity and electrical standards for safe operation.

Step 7 - Test It Out

• Give your wind turbine a test run once fully assembled.
• Monitor the voltage output. Tweak the blade angles if needed for maximum RPM.
• Secure bolts/joints which may have come loose after the test.
• Consult experts if your DIY turbine fails to generate expected power.

Tips

• Add bracing struts on the tower, rotor and tail for structural rigidity.
• Paint or seal your wind turbine to protect it from outdoor weathering.
• Position high up in very windy areas facing the prevailing wind direction.
• Periodically check electrical connections and mechanical parts for wear.
• Take safety precautions and keep away from the rotating blades.

With some scrap materials, tools and ingenuity, you can build a small wind turbine for your own home electricity needs. Just make sure to follow electrical safety guidelines. Proper placement is also key to generating optimal wind power.