How to Build a Wind Turbine from Scrap Materials

Building a wind turbine from scrap materials can be a fun and rewarding project. With some creativity and improvisation, you can build a simple wind turbine that actually generates electricity from wind power using common household items.

Planning Your Wind Turbine Design

The first step is to plan out your wind turbine design. Here are some key considerations:

Size and Scale

• Consider how large you want your wind turbine to be. Larger turbines can generate more power but will be harder to construct. Aim for around 1-2 feet in diameter for the turbine blades as a good starting point.

• Make sure to scale other components like the tower and generator accordingly. The tower height will affect wind speed.

Blades

• The blades are the most important part - they convert the wind energy into rotational motion. Measure and cut uniform blades from scrap material like wood, plastic or even cardboard.

• 3 blades is the most common and efficient design. Make them as lightweight as possible.

Generator

• The rotational motion of the blades spins a generator to produce electricity. A small DC motor can work when spun.

• An alternator from a car or bicycle can also generate AC power when spun at the right speed.

Tower

• The turbine needs to be raised high above the ground. The tower height improves wind exposure.

• Use scrap steel, wood or PVC piping to construct a tower to elevate the turbine. At least 10-20 feet tall if possible.

Finding Scrap Materials

Here are some common scrap items I can use to build my wind turbine:

Blades

• Plywood/wood boards - cut into uniform blade shapes. Can be sanded into airfoil shapes.

• Plastic containers - like bleach bottles, milk jugs, buckets. Cut in half and flatten to make blades.

• Cardboard - sturdy cardboard like shipping boxes can work. Create blade templates.

Generator

• DC motor - small hobby motors or toy car motors can generate electricity when spun.

• Alternator - rewire an old car alternator to generate AC current.

• Dynamo - an older bicycle dynamo can be repurposed as a generator.

Tower

• Steel pipes - plumbing pipes or scaffolding tubes make a sturdy tower.

• Wood boards - 2x4s or other wood can be used to build a tower frame.

• PVC/conduit - white PVC pipes are light and easy to work with.

Constructing the Wind Turbine

Once I have collected scrap materials, it's time to start building. Here is the general process:

1. Create the Turbine Blades

• Use the templates to cut uniform blades out of wood, plastic or cardboard.

• Sand wood into curved airfoil shapes. Flatten plastic blades. Tape cardboard together.

• Aim for 1-2 foot long blades for a small turbine. Bigger blades capture more wind.

2. Build the Turbine Hub

• The blades need to be mounted to a central hub that rotates.

• A thick wood disc or round plastic lid can be used as the hub.

• Drill holes at equal spacing to bolt the blades onto the hub using washers and nuts.

3. Attach to Generator

• Mount the generator (motor or alternator) to the hub in the center.

• Align so the shaft is perpendicular to the blade axis.

• Use a collar or coupler to connect the generator shaft to the hub.

4. Construct the Tower

• Build a tower frame from wood, steel or PVC. At least 10-20 feet tall.

• Add guy wires or supports for stability. Make sure it can handle the forces.

• Lift the turbine and attach it to the top of the tower.

Testing and Using Your Wind Turbine

Once constructed, it's time to test out your wind turbine:

• Check that the blades spin freely.

• Start at lower heights and use guy wires for support until operation is stable.

• Monitor the power output. Start small with LED lights before charging batteries.

• Position the turbine to face the prevailing winds in your area for maximum power.

• Maintain safety by keeping away from the spinning blades and preventing falls.

With some improvised designs and scavenged materials, you can build your own functional wind turbine. The renewable electricity generated can be used to power small devices or charge batteries. It's a unique way to learn about wind energy while reducing waste. By following these steps and refining as you go, you'll gain valuable skills and satisfy your inner tinkerer.