Introduction
Making your own small wind turbine from recycled materials is an excellent way to generate free renewable electricity. Small wind turbines can be built affordably using scraps and are simple enough for DIY hobbyists to construct. In this comprehensive guide, I will walk through all the steps, considerations, and tips for building your own scrap metal wind turbine from start to finish.
Choosing a Design
The most important factor when building a DIY wind turbine is choosing an appropriate design. Here are some key considerations when selecting a wind turbine design:
Rotor Type
- Horizontal axis - Most efficient design, rotor spins perpendicular to wind. More complex to build.
- Vertical axis - Simpler design, rotor spins parallel to wind. Less efficient.
For DIY projects, vertical axis turbines like Savonius or Darrieus models are recommended.
Number of Blades
- 2-3 blades provide good balance of simplicity, efficiency, and torque.
- More blades increase efficiency but also complexity.
Rotor Diameter
- The larger the rotor diameter, the more power it can generate.
- Aim for at least 3 ft diameter for small-scale turbines.
Generator Type
- Permanent magnet alternators are simplest to work with.
- Automotive alternators from junkyard scrap work well.
Once you've chosen a design, it's helpful to find DIY guides or schematics to reference during your build.
Materials and Tools Needed
Building a wind turbine from scrap requires creativity and resourcefulness. Here are some typical materials and tools you'll need:
Materials
- Rotor blades - Scrap metal sheets, plywood, plastic barrels, plastic buckets, etc.
- Hub - Metal disk or wheel, thick wood disk. Must attach blades.
- Shaft - Thick metal rod, pipe, tubing, or bar stock.
- Generator - Automotive alternator, permanent magnet motor, bicycle dynamo.
- Frame and tail - Scrap lumber, PVC pipe, steel pipes and plates.
- Hardware - Nuts, bolts, screws, bearings, adhesive, silicone, etc.
Tools
- Drill and drill bits
- Cutting tools - Jigsaw, hacksaw, Dremel, tin snips
- Welder, soldering iron
- Wrenches, pliers, screwdrivers
Shop around junkyards, hardware stores, and your own garage to find suitable materials for free or on the cheap.
Key Steps for Assembly
Once you have the materials and design, you're ready to start building. Follow these key steps:
1. Create the Rotor
The rotor converts wind energy into rotational energy. Follow your plans to construct the blades and attach them securely to the hub. Balance and alignment are very important.
2. Build the Frame
The frame holds the whole structure together. Make sure it is sturdy and allows the rotor to rotate freely. Add a tail for proper wind orientation.
3. Attach the Shaft
The shaft connects the rotor to the generator. Use a straight rod with properly sized fittings. Mount bearings to allow smooth spinning.
4. Add the Generator
Connect a permanent magnet alternator or other generator to the spinning shaft. Ensure proper alignment and minimal friction.
5. Wire the System
Using proper gauges, connect the generator outputs to your charge controller, battery bank, and inverter as needed.
6. Test It Out!
Do some initial low-speed tests. If all goes well, it's time to position your turbine in the wind and start generating power!
Tips for Optimizing Performance
Here are some tips to help your scrap metal wind turbine perform as well as possible:
- Find optimal wind location - Place high up on tower away from obstructions.
- Properly orient turbine - Position to face dominant wind direction.
- Use good alignment - Minimize friction and wiggle for smooth spin.
- Manage wind speed - Furling tail helps in high winds.
- Balance rotor - Even weight distribution prevents vibration.
- Maintain bearings - Lubricate and replace worn bearings when needed.
Don't get discouraged if it takes some tweaking to get your DIY wind turbine running perfectly. The satisfaction of generating your own power is well worth it!
Conclusion
Constructing small wind turbines from scrap materials makes renewable energy accessible for hobbyists and DIYers. Follow a proven plan, use sturdy and properly aligned parts, and optimize for your location. With some resourcefulness and creativity, you'll be generating free clean electricity from the wind in no time!