!

"# %" &'()* +

,-./ 0123-.4
Axial flux alternator windmill plans
8 foot and 4 foot diameter machines
Hugh Piggott -May 2003
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 B
!'6:H?I"8+(6#(5*JI"J'K
-5%8"*'I%("5
!"#$%&
TIese pIuns descrIbe Iow Lo buIId Lwo sIzes oI mucIIne.
TIe dIumeLer oI LIe Iurger wInd-roLor Is 8 IeeL |z.q m|.
TIe smuIIer mucIIne Ius q' dIumeLer |1.z m|.
TIe dIumeLer Is LIe wIdLI oI LIe cIrcuIur
ureu swepL by LIe bIudes.
TIe energy produced by wInd LurbInes
depends on LIe swepL ureu more LIun IL
does on LIe uILernuLor muxImum ouLpuL.
'"(%)*#(+)
TIe pIuns descrIbe Iow Lo buIId u permunenL mugneL
uILernuLor.
TIe uILernuLor cun be wIred Ior 1z, zq or q8-voIL buLLery
cIurgIng. EssenLIuIIy LIIs cIoIce onIy uIIecLs LIe sIze oI
wIre und LIe number oI Lurns per coII. BuL LIe Lower
wIrIng Ior LIe 1z-voIL versIon wIII be mucI IeuvIer LIun
LIe oLIers. And LIe sLuLor Ior LIe smuII mucIIne Is
dIIIerenL In LIIckness.
TIe uILernuLor desIgn Is InLegruLed InLo u sImpIe Lower-Lop
mounLIng urrungemenL (cuIIed u 'yuw beurIng'). A LuII
vune Iuces LIe LurbIne InLo LIe wInd. A buIIL In recLIIIer
converLs LIe eIecLrIcuI ouLpuL Lo DC, reudy Lo connecL Lo u
buLLery.
SmuII wInd LurbInes need Iow speed uILernuLors. ow
speed usuuIIy uIso meuns Iow power. TIe Iurge mucIIne
uILernuLor Is excepLIonuIIy powerIuI becuuse IL conLuIns zq
Iurge neodymIum mugneLs. TIe powerJspeed curve Ior u
very sImIIur desIgn Is sIown beIow. MuxImum ouLpuL Is
ubouL oo wuLLs under normuI cIrcumsLunces, buL IL Is
cupubIe oI more LIun 1ooo wuLLs Ior sIorL perIods.
TIe sLurLIng Lorque (Iorce requIred Lo geL IL movIng) Is
very Iow becuuse LIere ure no geurs, nor ure LIere uny
IumInuLIons In LIe uILernuLor Lo produce mugneLIc drug.
TIIs meuns LIuL LIe wInd LurbIne cun sLurL In very Iow
wInds und produce useIuI power. Power Iosses ure Iow In
Iow wInds so LIe besL possIbIe buLLery cIurge Is uvuIIubIe.
n IIgIer wInds LIe uILernuLor IoIds down LIe speed oI LIe
bIudes, so LIe mucIIne Is quIeL In operuLIon, und LIe
bIudes do noL weur ouL. You cun eusIIy sLop LIe wInd
LurbIne by sIorL-cIrcuILIng LIe ouLpuL wILI u 'bruke
swILcI'. TIese IeuLures muke LIe wInd LurbIne pIeusunL Lo
IIve wILI.
!"#$%&
TIe bIudes ure curved Irom wood wILI Iund LooIs. You
cun uIso use power LooIs II you preIer. Curved bIudes ure
good Ior IomebuIIders becuuse LIe process Is pIeusunL und
LIe resuILs ure quIck Ior u one-oII producL. MouIded
IIbregIuss bIudes ure usuuIIy beLLer Ior buLcI producLIon.
Wooden bIudes wIII IusL Ior muny yeurs.
,-)".*/ &1&(%2
TIe pIuns IncIude u descrIpLIon oI Iow Lo consLrucL u
IurIIng LuII Ior LIe Iurger mucIIne. TIIs LuII prevenLs
overIoud In IIgI wInds. TIIs Lype oI IurIIng sysLem Ius
been In use on ScoruIg Ior decudes und Ius pussed LIe LesL
oI LIme.
3*.(&
TIIs documenL cuLers Ior boLI AmerIcun reuders und
EuropeunJUK reuders, so LIe dImensIons ure In boLI
IncIes und mIIIImeLres. TIe mm IIgures ure In bruckeLs
|IIke LIIs|. n some oI LIe LIeory secLIons use meLrIc
uIone, becuuse IL mukes LIe muLIemuLIcs so mucI eusIer.
n some cuses, LIe meLrIc dImensIons wIII be dIrecL
conversIons oI LIe EngIIsI dImensIons, buL !"# %&'%().
TIe reusons ure LIuL dIIIerenL sIze mugneLs ure used Ior
LIe meLrIc desIgn, meLrIc wIre sIzes ure dIIIerenL Irom
AWG, und some ImporLunL pIysIcuI dImensIons ure
rounded oII Lo muke more sense In mm.
TIe US versIon LypIcuIIy uses u sLundurd GM Iub
(CILuLIon, CuvuIIer, eLc) wILI IIve sLuds und u beurIng uL LIe
buck. TIe beurIng IousIng needs u Iurge cIrcuIur IoIe In
LIe mounLIng uL LIe buck.
suggesL you use onIy one sysLem oI meusuremenL, eILIer
meLrIc or 'EngIIsI' und sLIck Lo LIuL sysLem. Your besL
cIoIce oI meusuremenL sysLem wIII depend on LIe mugneL
sIze you cIoose.
4+"%)#*5%&
MosL oI LIe dImensIons gIven ure nomInuI - LIe uccurucy Is
noL crILIcuI, so you need Lo noL IoIIow LIe druwIngs
sIuvIsIIy.
TIe sIupes oI LIe bIudes ure ImporLunL neur LIe LIp buL
mucI Iess so neur Lo LIe rooL (LIe Iurger, Inner end oI LIe
bIude).
TIe uILernuLor purLs musL be consLrucLed und ussembIed
wILI enougI uccurucy LIuL LIe mugneLs puss LIe coIIs
cenLruIIy us LIe mucIIne roLuLes.
DIAMETER
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 D
!'6:H?I"8+(6#(5*JI"J'K
LM.04.0N
-5%8"*'I%("5JJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJ B
BIudes................................................................................ z
AILernuLor.......................................................................... z
BIudes................................................................................ z
urIIng sysLem.................................................................. z
UnILs.................................................................................. z
ToIerunces......................................................................... z
O)"??+8AJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJ P
,"8K?:"> %"")?JJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJ Q
@+%78(+)? <"8 %:7 )+867 =+I:(57JJJJJJJJJJJJJJJJJJJJJJJJJJJJJ R
."%7? "5 #"8K?:"> ?+<7%AJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJ S
GENERA......................................................................... 8
SPECC HAZARDS ....................................................... 8
METAWORK.................................................................. 8
WOODWORKNG............................................................ 8
RESNS AND GUES....................................................... 8
MAGNETS ........................................................................ 8
EECTRCA.................................................................... 8
3TU/4 0!4M2VJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJ W
BIude power ...................................................................... q
BIude speed....................................................................... q
BIude number ................................................................... q
BIude sIupe....................................................................... q
L+8E(56 %:7 &)+*7?JJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJXC
STEP ONE Is Lo creuLe LIe Lupered sIupe. ......................1o
STEP TWO curvIng LIe LwIsLed wIndwurd Iuce..............1o
STEP THREE curvIng LIe LIIckness ............................... 11
STEP OUR Curve LIe curved sIupe on LIe buck oI LIe
bIude.................................................................................1z
STEP VE AssembIIng LIe roLor Iub. ...........................1z
!"#$%&!#'% #)$'%*JJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJXQ
G87>+8(56 %:7 &7+8(56 :'&JJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJXQ
DrIIIIng ouL LIe 1Jz' |1z mm| IoIes In LIe IIunge............16
Y+&8(I+%(56 %:7 +)%785+%"8 ="'5%?JJJJJJJJJJJJJJJJJJJJJJXZ
/8())(56 %:7 =+657% 8"%"8 >)+%7?JJJJJJJJJJJJJJJJJJJJJJJJJJJXW
@+K(56 %:7 I"() #(5*78JJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJXW
,(5*(56 %:7 I"()?JJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJBC
$"$+#%,+!" #)$'%*JJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJBX
L"557I%(56 %:7 I"()? JJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJBB
HInLs Ior soIderIng.......................................................... zz
SoIderIng LIe coII LuIIs .................................................... zz
TIe rIng neuLruI .............................................................. zz
TIe ouLpuL wIrIng........................................................... z
@+K(56 %:7 ?%+%"8 ="')* JJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJBD
Murk ouL LIe sIupe oI LIe sLuLor. ................................... z
CuL ouL LIe sLuLor sIupe In pIywood. ............................. zq
WIrIng exIL IoIes............................................................. zq
Screw LIe mouId Lo ILs buse............................................ zq
L+?%(56 %:7 ?%+%"8JJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJBQ
Dry run............................................................................ z
PuLLIng IL LogeLIer........................................................... z
RemovIng LIe cusLIng Irom LIe mouId........................... z6
0:7 =+657%9>"?(%("5(56 [(6 JJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJBR
@+K(56 %:7 %#" 8"%"8 ="')*?JJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJBS
ndex IoIe ....................................................................... z8
PurLs oI LIe mouIds .........................................................z8
L+?%(56 %:7 8"%"8? JJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJ BW
PrepuruLIon......................................................................zq
HundIIng LIe mugneLs.....................................................zq
Dry run ............................................................................zq
CIeckIng Ior mugneL poIurILy .........................................zq
PuLLIng IL LogeLIer ...........................................................zq
-.%",&/ 0*0#$1 #)$'%*JJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJ DC
WIy IurI? .........................................................................o
How LIe IurIIng LuII works ..............................................o
ConLroIIIng LIe LIrusL Iorce ............................................ 1
Y+&8(I+%(56 %:7 %+() :(567JJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJ DB
TIe LuII ILseII....................................................................
L'%%(56 "'% %:7 %+() E+57 JJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJ DP
@"'5%(56 %:7 :7+%?(5KJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJ DP
U??7=&)(56 %:7 +)%785+%"8JJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJ DQ
PrepuruLIon......................................................................
Hub und sIuIL..................................................................
Buck mugneL roLor...........................................................
TIe sLuLor.........................................................................
ronL mugneL roLor..........................................................6
07?%(56 %:7 +)%785+%"8 JJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJ DR
SIorL cIrcuIL LesLs ............................................................6
AC voILuge LesLs ...............................................................6
DC voILuge LesLs...............................................................6
L"557I%(56 %:7 87I%(<(78JJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJ DZ
L"557I%(56 %:7 &+%%78AJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJ DZ
uses or cIrcuIL breukers................................................. ;
ConnecLIons..................................................................... ;
Bruke swILcI .................................................................... ;
L:""?(56 ?'(%+&)7 #(87 ?(\7?JJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJ DZ
WIre Lype .........................................................................8
Y(%%(56 +5* &+)+5I(56 %:7 &)+*7? JJJJJJJJJJJJJJJJJJJJJJJJJ DW
CIeckIng LIe LruckIng .....................................................q
BuIuncIng LIe roLor..........................................................q
Ine LunIng ......................................................................q
U//-0-M.UT -.YM2@U0-M.JJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJ PC
O'A7* %"#78 (*7+? JJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJ PC
L"5%8"))(56 %:7 &+%%78A I:+867 8+%7JJJJJJJJJJJJJJJJJJJJ PX
SIunL reguIuLor cIrcuIL .................................................... q1
IsL oI componenLs requIred........................................... q1
1?(56 >")A7?%78 87?(5JJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJ PB
MouId prepuruLIon..........................................................qz
N=+)) =+I:(57 ?'>>)7=75%JJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJ PD
BIudes ..............................................................................q
BeurIng Iub .....................................................................q
TIe sIuIL ..........................................................................qq
RoLor mouIdIng ...............................................................qq
SLuLor mouId....................................................................q6
AssembIy oI LIe sLuLor.....................................................q6
TIe yuw beurIng .............................................................. q;
TIe LuII beurIng und LuII .................................................. q;
WIrIng up LIe buLLery......................................................q8
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 P
!'6:H?I"8+(6#(5*JI"J'K
O)"??+8A
!"#AILernuLIng currenL us produced by LIe uILernuLor.
!$$%&'()* - USA word Ior 'LIreuded' or 'spun' rod or
sLuddIng
+'),( ./0%1& - A swILcI used Lo sIorL-cIrcuIL LIe wIres
Irom LIe uILernuLor so LIuL IL sLops.
")%)$2.% - A cIemIcuI used Lo muke LIe poIyesLer resIn seL
soIId. CuLuIysL reucLs wILI 'ucceIeruLor' uIreudy presenL In
LIe resIn mIx. TIe IeuL oI reucLIon seLs LIe poIyesLer.
")3)$0(' - A muke oI cur. TIe cuvuIIer In LIe UK Is noL LIe
sume us LIe CuvuIIer In LIe USA buL boLI Iuve useIuI
wIeeI Iubs.
4" - dIrecL currenL wILI u posILIve und u neguLIve sIde, us
In buLLery cIrcuILs.
40)5(%(' - TIe dIsLunce Irom one sIde oI u cIrcIe Lo
unoLIer. TIe wIdLI oI u dIsk rIgIL ucross LIe mIddIe.
4')6 - A Iorce exerLed by LIe wInd on un objecL. Drug Is
puruIIeI Lo LIe wInd dIrecLIon uL LIe objecL. (see IIL)
4'78 - Used Iere Lo descrIbe u cerLuIn meusuremenL oI LIe
sIupe oI u wIndmIII bIude. TIe 'drop' uIIecLs LIe ungIe oI
LIe bIude Lo LIe wInd.
9$:; - TIe 'sLuII' oI mugneLIsm. SImIIur Lo 'currenL' In
eIecLrIcILy. L cun be vIsuuIIsed us 'IInes' comIng ouL oI one
poIe und reLurnIng Lo LIe oLIer.
9:'$0<6 - A proLecLIve ucLIon LIuL reduces exposure Lo
vIoIenL wInds by IucIng LIe bIudes uwuy Irom LIem.
=06 - A devIce used Lo IoId LIe mugneLs In pIuce beIore
seLLIng LIem In resIn.
>()*0<6 (*6( - TIe edge oI u bIude LIuL wouId sLrIke un
objecL pIuced In ILs puLI us LIe roLor spIns.
>0?% - A Iorce exerLed by LIe wInd on un objecL. IIL Is uL
rIgIL ungIes Lo LIe wInd dIrecLIon uL LIe objecL. (see Drug)
@7:$* - A sIuped conLuIner In wIIcI resIn cusLIngs ure
Iormed. TIe mouId cun be dIscurded uILer LIe cusLIng Ius
seL.
@:$%05(%(' - A versuLIIe eIecLrIcuI LesL InsLrumenL, used Lo
meusure voILuge, currenL und oLIer purumeLers.
A(7*250:5 - TIe nume gIven Lo u Lype oI permunenL
mugneL conLuInIng neodymIum, Iron und boron. TIese
mugneLs ure very sLrong und geLLIng cIeuper uII LIe LIme.
B??.(% - An eccenLrIc posILIon, oII cenLre.
C&).( - TIe LImIng oI LIe cycIIcuI uILernuLIon oI voILuge In
u cIrcuIL. DIIIerenL pIuses wIII peuk uL dIIIerenL LImes.
C7$2(.%(' - A Lype oI resIn used In IIbregIuss work. AIso
suILubIe Ior mukIng cusLIngs.
C7/(' - LIe ruLe oI deIIvery oI energy
D(1%0?0(' - A semIconducLor devIce LIuL Lurns AC InLo DC
Ior cIurgIng LIe buLLery.
D77% - TIe wIdesL purL oI LIe bIude neur Lo LIe Iub uL LIe
cenLre oI LIe roLor.
D7%7' - A roLuLIng purL. MugneL roLors ure LIe sLeeI dIsks
curryIng LIe mugneLs pusL LIe sLuLor. RoLor bIudes ure LIe
'propeIIer' drIven by LIe wInd und drIvIng LIe mugneL
roLors.
E7$*('0<6 - A meLIod Ior mukIng eIecLrIcuI connecLIons
beLween wIres usIng u IoL 'Iron' und couLIng everyLIIng
wILI moILen soIder.
E%)%7' - An ussembIy oI coIIs embedded In u sIub oI resIn
Lo Iorm purL oI LIe uILernuLor. TIe mugneLs Induce u
voILuge In LIe coIIs und we cun use LIIs Lo cIurge u buLLery.
E%2'(<( 57<75(' - A nusLy smeIIIng soIvenL In LIe
poIyesLer resIn mIx.
F)$1:5 87/*('# A cIeup IIIIer powder used Lo LIIcken LIe
resIn und sIow ILs reucLIon (prevenL IL overIeuLIng).
F)0$ # A projecLIng vune mounLed on u boom uL LIe buck oI
LIe wIndmIII used Lo sLeer IL InLo or ouL oI LIe wInd
uuLomuLIcuIIy.
F)8 - u LooI Ior mukIng LIreud InsIde IoIes so you cun IIL u
screw InLo LIe IoIe.
F&':.% - TIe Iorce oI LIe wInd pusIIng LIe mucIIne
buckwurds.
F7/(' - TIe musL supporLIng LIe wIndmIII.
F')0$0<6 (*6( - TIe bIude edge IurLIesL Irom LIe IeudIng
edge. TIe LruIIIng edge Is sIurpened, so us Lo reIeuse LIe
pussIng uIr wILIouL LurbuIence.
G(*6(. - Tupered pIeces oI wood used Lo buIId up LIe
bIude LIIckness und Increuse ILs ungIe Lo LIe wInd neur LIe
rooL.
G7',80(1( - TIe pIece oI wood or meLuI beIng sIuped In
LIe worksIop.
H)/ I()'0<6 - LIe swIveI uL LIe Lop oI LIe Lower on wIIcI
LIe wIndmIII Is mounLed. TIe yuw beurIng uIIows LIe
wIndmIII Lo Iuce LIe wInd.
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 Q
!'6:H?I"8+(6#(5*JI"J'K
,"8K?:"> %"")?
MECHANCA
TOOS
eIecLrIc weIder
'suws-uII'
oxy-uceLyIene LorcI
weIdIng musk
cIIppIng Iummer
vIce
G cIumps
pIIIur drIII
cordIess drIII
IundIeId eIecLrIc drIII
-- 1Jz" |1mm| cIuck
drIII bILs
IoIesuws
1Jz" |M1z| Lup
ungIe grInder
beIL sunder
cuL-oII mucIIne
Iucksuw
coId cIIseI
Iummer
cenLre puncI
IIIes
LIn snIps
Lupe meusure
sLeeI ruIer
seL squure
proLrucLor
scrIber
cIuIk
compusses
ungIeJbeveI guuge
spIrIL IeveI
vernIer cuIIpers
eur proLecLors
suIeLy gIussesJgoggIes
Iuce musks
screwdrIvers
pIIers
vIce grIps
1o"udjusLubIe wrencI
combInuLIon
wrencIes J8"-Jq"
|1o-1qmm|
sockeL wrencIes und
ruLcIeLs 1o-1qmm
WOODWORKNG
TOOS
vIce
G cIumps
Iummer
wooden muIIeL
druw knIIe
spoke sIuve
pIunes Iurge und
smuII
wood cIIseI
oIIsLone
jIg suw
screwdrIvers
Iundsuw
cIrcuIur suw
pencII
Lupe meusure
sLeeI ruIer
seL squure
spIrIL IeveI
cuIIpers
PASTCS ETC
TOOS
muILImeLer
surIormJrusp
weIgIIng scuIes
spoons, knIves Ior
mIxIng
suIeLy gIusses
Iuce musks
screwdrIvers
knIIe
scIssors
IeIL pen
soIderIng Iron
pencIIs
Lupe meusure
sLeeI ruIer
spIrIL IeveI

*+),-&&%!-".)
,"!)./%0&-)
WeIdIng rods, grIndIng
dIsks, Iucksuw bIudes.
Epoxy gIue und bondo
Ior mIsc. repuIrs.
eud IIusIIng Ior
buIuncIng bIudes
(1J8" x 1z" x 1z" upprox.
pIece)
HeuLsInk compound Ior
recLIIIer mounLIng
1"/- -2#3% #""&) 4"3
#5- )/%&&-3 /%,5+!-
1" dIumeLer wood
borIng bIL Ior mouIds.
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 R
!'6:H?I"8+(6#(5*JI"J'K
@+%78(+)? <"8 %:7 )+867 =+I:(57
BLADE WOOD
Pieces
Material Length Width Thick
3
blades
Light, straight
grained wood
4 feet
[1200mm]
6 "
[150 mm]
1 1/2"
[37
mm]
1
wedges
Off-cut of
wood, with
some straight
-grained
portions
Enough to
find some
nice
portions
Over 3"
[75mm]
1 1/2"
[37
mm]
PLYWOOD ETC.
Pieces
Material Length Width Thick
2
lids
Hardboard 16" [400] 16" [400] 1/8" [3 ]
1
jig
Hardboard
or plywood
12" [300] 12" [300] 1/4" [6]
2
island
Plywood
for magnet
6" [158] 6" [158] 1/2" larger
[9] smaller
1
tail
vane
Exterior
plywood for
tail vane
36"
[900 mm]
24"
[600]
3/8"
[9 mm]
2
hub
disks
Exterior
quality
plywood
10"
[250mm]
10 "
[250mm]
1
stator
Plywood 24" [600] 24" [600]
3
coil
winder
Plywood 4"
[100 mm]
3"
[75mm]
1/2"
[13 mm]
2
lid and
base
Smooth
faced
board
24" [600] 24" [600] 3/4" [19]
suggested
size
4
rotors
Floor board 16" [400] 16" [400] 3/4" [19]
STEEL AND ALUMINIUM
Pieces
Steel pipe Length Overall
Diam.
Wall
Thick
1Yaw
bearg.
2" nominal 12"
[300 mm]
2 3/8"
60.3 OD
1/8"
[3mm]
1Yaw
brg.
1 1/2 "
nominal bore
16"
[400 mm]
1 7/8"
[48 mm]
1/8"
[3mm]
1 Tail
boom
1 1/4"
nominal bore
4' 6"
[1350 mm]
1 5/8"
[42.2]
1/8"
[3mm
1 tail
hinge
1 " nominal
bore
8"
[200 mm]
1 5/16"
[33.4]
1/8"
[3mm
Pieces
Steel disk Diam. Thick Hole
2 Magnet rotor
disks
12 " O.D.
[300 mm]
5/16"
8 mm
2 1/2
[65 ]
1 tail
bearin
g cap
Steel plate
disk or
square
1 5/8"
[42.2]
minimum
5/16"
[8mm]
1 yaw
bearin
g cap
Steel plate
disk or
square
2 1/2"
[65]
5/16"
[8mm]
Pieces
Material Length Width Thic
1
tail
hinge
Steel plate 4"
[100]
2 1/4"
[56 mm]
3/8"
[10]
1
tail
Steel bar 12" [300]
approx.
1 1/2"[30] 5/16'
[8]
2 Steel angle 10 1/2"
[267 mm]
2"
[50 mm]
1/4"
[6 ]
2 Steel angle 2"
[50mm]
2"
[50 mm]
1/4"
[6 ]
1 Steel angle 4"
[100 mm]
2"
[50 mm]
1/4"
[6 ]
1 Aluminium
angle or
channel
9"
[220 mm]
2"
[50]
3/16"
[5
mm]
MAGNETS
24 Magnet blocks 2 x 1 x 1/2" grade 35 NdFeB
Item 76 from www.wondermagnet.com
[46 x 30 x 10 mm grade 40 NdFeB see below
UK SOURCES OF PARTS
Fibreglass resin
etc
Glasplies 2, Crowland St. Southport,
Lancashire PR9 7RL
(01704) 540 626
Magnets
CERMAG Ltd. 94 Holywell Rd, Sheffield
SA4 8AS (0114) 244 6136
or <sales@magna-tokyo.com>
Winding wire
EC WIRE LTD (01924) 266 377
Percy Hawkins(01536) 523 22
FARNELL www.farnell.com
JPR Electronics www.jprelec.co.uk
Rectifiers and
other
components
www.Maplin.co.uk
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 Z
!'6:H?I"8+(6#(5*JI"J'K
STEEL FASTENERS
Pieces
Material Length Width
1
mounts
Stainless steel
all-thread rod
5'
[1.5 m]
1/2"
[M12]
40 Stainless steel
nuts
1/2"
[M12]
10 Stainless steel
washers
1/2"
[M12]
4
for rotor
moulds
Bolts,
nuts +
washers
3"
[70 mm]
1/2"
[12 mm]
4
coil former
Nails or pins 4" ?
[100 mm ?]
3/16"
[5 mm]
1
winder
Stud or bolt
(winder shaft)
6" approx.
[150 mm]
3/8"
[10 mm]
5
winder
Nuts and
washers
3/8"
[10 mm]
3
tail vane
Bolts, nuts
washers
2 1/2"
[60 mm]
3/8"
[M10]
2
heatsink
Bolts and nuts 1" [25] 1/4" [6]
6
rectifiers
Bolts and nuts 1" [25] 3/16" [5]
100 Wood screws 1 1/4" [32 mm]
FIBERGLASS RESIN
Quantity Material
6lbs
[2.5 kg]
Polyester casting resin or fiberglass resin in
liquid form (premixed with accelerator).
Peroxide catalyst to suit.
5 lbs.
[2.2 kg]
Talcum powder
3' x 3'
[1 x 1 m]
Fiberglass cloth (or use chopped strand mat)
1 ounce per sq. foot= [300g per sq. metre]
Wax polish
Silicone sealant
WIRE ETC
Weight Material Turns per coil
& size
Voltag
80 turns of #15 wire
[90 turns of 1.4 mm]
12 V
160 turns of #18 wire
[180 turns of 1 mm]
24V
6 lbs.
[3 kg]
for ten
coils
Enamel
winding
wire, called
magnet wire
www.otherp
ower.com
320 turns of #21 wire
[360 turns 0.7 mm]
48V
#14 [2 mm] or similar 12-V, 30'
[10 m]
Flexible wire
with high
temperature
insulation
#18 [.75 MM] bundled
in a protective sleeve
24V or
48V
3' [1 m] Resin cored
solder wire
3' [1 m] Insulation
sleeving
Large enough to fit
over the solder joints
5 Bridge
rectifiers
35A 6-800V single phase
http://www.rfparts.com/bridge.htm
1 Connector
block
BEARING HUB
1 Automotive rear hub with flanged shaft for
convenient mount to wind turbine.
1]
^42N-M.
!13
SHAFT
HUB
3"
5
.
5
"
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 S
!'6:H?I"8+(6#(5*JI"J'K
."%7? "5 #"8K?:"> ?+<7%A
67879':
WorksIop suIeLy depends on correcL beIuvIour. TIere
ure InLrInsIc dungers. Be uwure oI LIe rIsks Lo yourseII
und oLIers und pIun your work Lo uvoId Iuzurds.
ProLecLIve cIoLIIng wIII reduce LIe rIsks, buL wILIouL
uwureness LIe worksIop wIII noL be suIe.
Keep LIe worksIop LIdy. AvoId LruIIIng Ieuds, precurIous
buckeLs or oLIer unnecessury Iuzurds, wIIcI peopIe
couId LrIp over or spIII.
WuLcI ouL Ior oLIers, Lo uvoId puLLIng LIem uL rIsk und
bewure oI wIuL LIey mIgIL do wIIcI couId puL you uL
rIsk.
Weur proLecLIve cIoLIIng - eye proLecLIon, gIoves, IeImeL,
musk, eLc us upproprIuLe Lo prevenL dunger. AvoId Ioose
cIoLIIng or IuIr, wIIcI couId be Lrupped In roLuLIng LooIs
und puIIed Inwurds.
Tuke cure wIen IundIIng LooIs wIIcI couId cuL or Injure
yourseII or oLIers. ConsIder LIe consequences oI LIe LooI
sIIppIng or LIe workpIece comIng Ioose. ALLend Lo your
work, even wIen cIuLLIng Lo oLIers.
;<7=>,>= ?'@'9A;
B74':CD9E
GrIndIng, sundIng, drIIIIng eLc cun produce IIgI veIocILy
dusL und debrIs. AIwuys weur u musk wIen grIndIng.
Tuke cure LIuL uny spurks und grIL ure dIrecLed InLo u suIe
zone wIere LIey wIII noL Injure unyone, or cuuse IIres.
ConsIder Iow LIe LooI mIgIL come InLo conLucL wILI
IIngers or oLIer vuInerubIe body purLs.
WeIdIng, drIIIIng eLc mukes meLuI IoL, so Luke cure wIen
IundIIng meLuIwork durIng IubrIcuLIon.
WeIdIng sIouId Luke pIuce In u screened spuce wIere LIe
spurks wIII noL bIInd oLIers. Weur uII proLecLIve cIoLIIng
IncIudIng musk. Do noL InIuIe LIe Iumes. ProLecL LIe
eyes wIen cIIppIng oII sIug. Do noL LoucI IIve eIecLrodes
or bure cubIe.
SLeeI mecIunIsms cun IuII or IoId In sucI u wuy us Lo
breuk Loes or IIngers. TIInk uIeud wIen IundIIng sLeeI
IubrIcuLIons Lo prevenL Injury. CIump LIe workpIece
secureIy.
Tuke greuL cure wIen IIILIng sLeeI ussembIIes, Lo uvoId
buck Injury. Keep weII cIeur oI Lowers und poIes LIuL
couId IuII on your Ieud. Weur u suIeLy IeImeL wIen
workIng under wInd LurbInes.
CDDACD9E>86
Tuke cure wILI sIurp LooIs. CIump LIe workpIece
secureIy und consIder wIuL wouId Iuppen II LIe LooI
sIIps. WuLcI ouL Ior oLIers.
Weur u dusL musk wIen sundIng. Do noL Iorce oLIers Lo
breuLIe your dusL. Tuke LIe job ouLsIde II possIbIe.
Wood spIInLers cun peneLruLe your skIn. Tuke cure wIen
IundIIng wood Lo uvoId cuLLIng yourseII.
97;>8; '8A 6:37;
TIe soIvenLs In resIns cun be LoxIc. Weur u musk und
muke sure LIere Is udequuLe venLIIuLIon.
AvoId skIn conLucL wILI resIns. Use dIsposubIe gIoves.
PIun your work Lo uvoId spIIIuge or IundIIng oI pIusLIc
resIns und gIues. Be especIuIIy cureIuI oI spIusIIng resIn
In LIe eyes.
B'6874;
MugneLs wIII eruse mugneLIc medIu sucI us credIL curds,
sIm curds, cumeru memory curds, und dumuge wuLcIes.
Remove sucIIIke Irom pockeLs beIore IundIIng mugneLs.
MugneLs IIy LogeLIer wILI remurkubIe Iorce. Bewure oI
LruppIng your IIngers. TIIs Is LIe mosL IIkeIy cuuse oI
smuII InjurIes. SIIde mugneLs LogeLIer sIdewuys wILI
exLreme cuuLIon.
7:7=49>=':
CIeck Ior dungerous voILuges beIore IundIIng uny
wIrIng.
BuLLery voILuge sysLems ure mosLIy Iree Irom dungerous
voILuges, buL LIere Is u sIock Iuzurd Irom wInd LurbInes
runnIng dIsconnecLed Irom LIe buLLery. Under LIese
condILIons LIe ouLpuL voILuge cun rIse Lo dungerous
IeveIs.
Even uL Iow voILuges LIere Is u dunger oI burns Irom
eIecLrIc urcs or sIorL cIrcuILs. AII cIrcuILs Irom buLLerIes
sIouId Iuve Iuses or cIrcuIL breukers Lo prevenL
susLuIned sIorL cIrcuILs cuusIng IIres.
Be especIuIIy cureIuI wILI buLLerIes. MeLuI objecLs
conLucLIng buLLery LermInuIs cun cuuse Iurge spurks und
burns. Gus InsIde LIe buLLery cun be IgnILed, cuusIng un
expIosIon LIuL spuLLers ucId In LIe eyes. AcId wIII burn
cIoLIIng und skIn. AvoId conLucL, und IIusI uny uIIecLed
purLs wILI umpIe wuLer. Tuke cure wIen IIILIng und
movIng buLLerIes Lo prevenL buck Injury or ucId spIIIs.
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 W
!'6:H?I"8+(6#(5*JI"J'K
3TU/4 0!4M2V
!"#$% F+G%)
TIe roLor bIude ussembIy Is LIe engIne powerIng LIe
wInd generuLor. TIe bIudes produce mecIunIcuI power
Lo drIve LIe uILernuLor. TIe uILernuLor wIII converL LIIs
InLo eIecLrIcuI power. BoLI Lypes oI power cun be
meusured In wuLLs.
L's u good Ideu Lo use meLrIc unILs Ior uerodynumIc
cuIcuIuLIons. TIe power (wuLLs) In LIe wInd bIowIng
LIrougI LIe roLor Is gIven by LIIs IormuIu6
789 2 %+3:;-!)+#( 2 )'-<#:%3-% 2 '+!;)<--;
=
(wIere uIr densILy Is ubouL 1.z kgJm

)
TIe bIudes cun onIy converL uL besL IuII oI LIe wInd`s
LoLuI power InLo mecIunIcuI power. n prucLIce onIy
ubouL z -% Is u more LypIcuI IIgure Ior IomebuIIL
roLor bIudes. Here Is u sImpIer ruIe oI LIumb:
>&%;- <"'-3 ? @A7B 2 C+%/-#-3
9
2 '+!;)<--;
=
? @A7B 2 D9AE /-#3-)F
9
2 D7@ /-#3-)8)-,"!;F
=
? @A7B 2 G 2 7@@@ ? H@@ '%##) %<<3"2A
(z.qm dIumeLer roLor uL 1o meLresJsec or zz mpI)
C+%/-#-3 Is very ImporLunL. I you doubIe
LIe dIumeLer, you wIII geL Iour LImes us
mucI power. TIIs Is becuuse LIe wInd
LurbIne Is ubIe Lo cupLure more wInd.
I+!;)<--; Is even more ImporLunL. I
you cun geL doubIe LIe wIndspeed, you wIII
geL eIgIL LImes us mucI power.
!"#$% &F%%$
TIe speed uL wIIcI LIe bIudes roLuLe wIII depend on Iow
LIey ure Iouded. I LIe uILernuLor Ius IIgI Lorque und Is
Iurd Lo Lurn, LIen LIIs muy IoId LIe speed down Loo Iow.
I LIe wIrIng Is dIsconnecLed und eIecLrIcILy producLIon Is
dIsubIed, LIe roLor wIII ucceIeruLe und 'run uwuy` uL u
mucI IIgIer speed.
RoLor bIudes ure desIgned wILI speed In mInd, reIuLIve Lo
LIe wInd. TIIs reIuLIonsIIp Is known us 'LIp speed ruLIo`
(Lsr). TIp speed ruLIo Is LIe speed LIe bIude LIps LruveI
dIvIded by LIe wIndspeed uL LIuL LIme.
n some cuses LIe LIps oI LIe bIudes move IusLer LIun LIe
wInd by u ruLIo oI us mucI us 1o LImes. BuL LIIs Lukes
LIem Lo over zoo mpI, resuILIng In noIsy operuLIon und
rupId erosIon oI LIe bIudes edges. recommend u Iower
LIp speed ruLIo, uround ;.
We ure buIIdIng u roLor wILI dIumeLer 8 IeeL |z.q
meLres|. We wunL Lo know wIuL rpm IL wIII run uL besL In
u ; mpI | mJs| wInd wIen IIrsL sLurLIng Lo produce
useIuI power.
J</ ? '+!;)<--; 2 #)3 2 G@8,+3,./4-3-!,-
?= 2 K 2 G@ 8D9AE 2 =A7EF? 7GK 3</
!"#$% *-2H%)
PeopIe oILen usk WIy noL udd more bIudes und geL
more power? L Is Lrue LIuL more bIudes wIII produce
more Lorque (LurnIng Iorce), buL LIuL does noL equuLe Lo
more power. MecIunIcuI power Is speed muILIpIIed by
Lorque. or eIecLrIcILy producLIon you need speed more
LIun you need Lorque. ExLru bIudes IeIp LIe mucIIne Lo
sLurL Lo Lurn sIowIy, buL us LIe speed Increuses LIe exLru
drug oI uII LIose bIudes wIII IImIL Iow mucI power IL cun
produce. MuILIbIuded roLors work besL uL Iow LIp speed
ruLIos.
usL LurnIng bIudes generuLe mucI more IIIL per squure
IncI oI bIude surIuce LIun sIow ones do. A Iew, sIender
bIudes spInnIng IusL wIII do LIe sume job us muny wIde
ones spInnIng sIowIy.
!"#$% &I#F%
Any roLor desIgned Lo run uL LIp speed ruLIo ; wouId need
Lo Iuve u sImIIur sIupe, regurdIess oI sIze. TIe
dImensIons ure sImpIy scuIed up or down Lo suIL LIe
cIosen dIumeLer.
We specIIy LIe sIupe uL u serIes oI sLuLIons uIong LIe
IengLI oI LIe bIude. AL eucI sLuLIon LIe bIude Ius 'cIord
wIdLI`, 'bIude ungIe' und 'LIIckness'. WIen curvIng u
bIude Irom u pIece oI wood (u 'workpIece`) we cun
InsLeud specIIy LIe '+;#5 oI LIe workpIece und uIso wIuL
cuII LIe ';3"<L. TIese meusuremenLs wIII LIen produce
LIe correcL cIord wIdLI und bIude ungIe. TIe drop Is u
meusuremenL Irom LIe Iuce oI LIe workpIece Lo LIe
LruIIIng edge oI LIe bIude.
TIe sIupe oI LIe bIude !-%3 #5- 3""# muy vury Irom
one wInd LurbIne Lo unoLIer. A sLrongIy LwIsLed und
Lupered sIupe Is IdeuI. BuL In some cuses u mucI Iess
pronounced LwIsL Is uIso successIuI. preIer LIe sLrong
LwIsL und Luper becuuse
u) IL Is sLrong
b) IL Is sLurLs up beLLer Irom resL,
und c) LIInk IL Iooks beLLer.
n IucL IL Is noL goIng Lo muke u Iuge dIIIerence II LIe
rooL Is u dIIIerenL sIupe. TIe bIude rooL sIupe wIII
probubIy be deLermIned more by prucLIcuI Issues sucI us
uvuIIubIe wood und LIe deLuIIs oI Iow Lo mounL IL Lo LIe
uILernuLor LIun by uerodynumIc LIeory.
WIDTH
LEADING
EDGE
OUTLINE OF WOODEN WORKPIECE
TRAILING
EDGE
BLADE
ANGLE
DROP
CHORD WIDTH
THICKNESS
BLADE STATIONS
BLADE SECTION
DIAMETER
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 XC
!'6:H?I"8+(6#(5*JI"J'K
L+8E(56 %:7 &)+*7?
*%#-3+%&)
PIeces MuLerIuI engLI WIdLI TIIck
IgIL,
sLruIgIL
gruIned wood
q IeeL
|1zoomm|
6 "
|1o mm|
1 1Jz"
|;
mm|
TIe wood sIouId be weII seusoned und Iree oI sup. L Is
someLImes possIbIe Lo cuL severuI 'bIunks` ouL oI u Iurge
beum, uvoIdIng knoLs. You cun gIue u pIece onLo LIe sIde
oI LIe workpIece Lo muke up LIe exLru wIdLI uL LIe rooL.
Do noL Increuse LIe IengLI by gIuIng, us LIIs wIII weuken
LIe bIude.
CIeck Ior uny LwIsL on LIe Iuce oI LIe workpIece, usIng u
spIrIL IeveI ucross LIe Iuce uL InLervuIs uIong ILs IengLI. I
LIe wood Is IeveIIed uL one poInL, IL sIouId LIen be IeveI
uL uII poInLs. I LIe pIece Is LwIsLed LIen IL muy be
necessury Lo use dIIIerenL LecInIques Lo murk ouL
uccuruLeIy LIe LruIIIng edge (see nexL puge).
;47< D87 .& (+ 5)%#(% (I% (#F%)%$ &I#F%J
TIe bIude Is nurrow uL LIe LIp und Iuns ouL InLo u wIder
cIord neur LIe rooL. TIIs LubIe sIows LIe wIdLI you
sIouId uIm Ior uL eucI sLuLIon. You muy wIsI Lo do LIe
murkIng ouL once wILI u LempIuLe oI LIIn bourd. TIen
cuL ouL und use LIe LempIuLe Lo murk LIe ucLuuI bIudes.
sLuLIon wIdLI
1 6 " 1o mm
z q Jq" 1zo mm
1J16" 1oo mm
q 1J8" 8o mm
z Jq" ;o mm
6 z J8" 6o mm
Murk ouL LIe sLuLIons by meusuremenL Irom LIe rooL
oI LIe workpIece.
Druw u IIne uround LIe workpIece uL eucI sLuLIon,
usIng u squure (IInes sIown doLLed).
Murk LIe correcL wIdLI uL eucI sLuLIon, meusurIng
Irom LIe IeudIng edge, und joIn LIe murks up wILI u
serIes oI pencII IInes.
CuL uIong LIese IInes wILI u bundsuw.
AILernuLIveIy you cun curve uwuy LIe unwunLed wood
wILI u druwknIIe. Or crosscuL IL uL InLervuIs und cIop IL
ouL wILI u cIIseI. n uny cuse LIe IInuI cuL Iuce sIouId be
mude neuL und squure Lo LIe resL oI LIe pIece. Muke eucI
bIude LIe sume.
;47< 4CD 5#)K.*/ (I% (G.&(%$ G.*$G#)$ L#5%
TIe wIndwurd Iuce oI LIe bIude wIII be ungIed, buL
somewIuL IIuL, IIke LIe undersIde oI un uIrcruIL wIng.
TIe ungIe wIII be sLeeper (removIng more wood) uL LIe
rooL LIun IL Is uL LIe LIp. TIe reuson wIy bIude-ungIe
sIouId cIunge Is becuuse LIe bIude-speed becomes
sIower us we upproucI LIe cenLre. TIIs uIIecLs LIe ungIe
oI LIe uppurenL uIr veIocILy sLrIkIng LIe bIude uL eucI
sLuLIon.
SLurL by murkIng LIe sLuLIons (wILI u squure) on LIe
Iuce you cuL In SLep One.
TIen murk LIe 'drop' on eucI oI LIese new IInes,
meusurIng Irom LIe Iuce oI LIe wood us sIown beIow
und murkIng LIe posILIon oI LIe LruIIIng edge uL eucI
sLuLIon.
sLuLIon drop
1 1 1Jz" ; mm
z 1 z mm
;J16 1z mm
q 1Jq 6 mm
1J8 mm
6 1J16 z mm
JoIn LIese murks Lo Iorm LIe IIne oI LIe LruIIIng edge.
TIe IeudIng edge Is LIe oLIer corner oI LIe
workpIece.
TIe 'drop` neur LIe rooL Is noL Iurge enougI Lo gIve LIe
besL bIude ungIe. n sLep sIx you wIII use u wooden
'wedge' Lo buIId up LIe IeudIng edge, und doubIe LIe
eIIecLIve drop. TIIs wedge creuLes LIe desIred bIude-
ungIe wILIouL needIng sucI u LIIck workpIece. euve u
PENCIL LINES AT STATIONS
MARK OUT THE SHAPE ON THE FACE OF THE WORKPIECE
30
LEADING EDGE
CUT ALONG THIS LINE
(CUT THE 30
DEGREE ANGLE
LATER)
LEADING
EDGE
DIRECTION
OF MOTION
TRAILING
EDGE
CENTRE OF ROTOR
TIP
WEDGE
wedge
A SERES O SECTONA VEWS O THE BADE, TO NDCATE HOW THEY
CHANGE N SZE AND ANGE BETWEEN THE TP AND THE ROOT O THE BADE
ROOT
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 XX
!'6:H?I"8+(6#(5*JI"J'K
porLIon oI LIe Iuce uncuL wIere LIe wedge wIII IIL. n LIIs
ureu uround LIe IIrsL sLuLIon, you wIII be cuLLIng u Iuce
beLween LIe LruIIIng edge und LIe ouLIIne oI LIe wedge
IooLprInL.
Remove uII
LIe wood
ubove LIe
LruIIIng edge
IIne, so LIuL
you cun pIuce
u sLruIgIL edge
beLween LIe
IeudIng und LruIIIng edges.
n LIIs wuy you wIII be IormIng LIe LwIsLed wIndwurd
Iuce oI LIe bIude. use u druwknIIe und u spoke-sIuve Lo
do LIe Inner purL, und u pIune Is useIuI on LIe sLruIgILer
purL. You cun use u sunder II you preIer. Tuke cure Lo be
precIse In LIe ouLer purL neur LIe LIp wIere LIe bIude
ungIe Is crILIcuI. C" !"# 3-/"M- %!( "4 #5- &-%;+!N
-;N-, buL work rIgIL up Lo IL, so LIuL LIe ungIed Iuce
sLurLs rIgIL Irom LIIs corner oI LIe wood.
euve LIe bIude rooL unLoucIed, so LIuL IL cun be IILLed
InLo LIe Iub ussembIy. TIe Iub wIII be consLrucLed by
cIumpIng LIe bIudes beLween Lwo pIywood dIsks (see sLep
IIve). TIe curvIng oI LIe wIndwurd Iuce ends wILI u
rump uL LIe Inbourd end. TIIs rump Is guIded by IInes,
wIIcI meeL uL u poInL jusL ouLsIde LIe Iub ureu. TIe IIne
on LIe Iurger Iuce Ius Lwo Iegs - one Ior LIe wedge und
one Ior LIe rump.
"&(1,0<6 %&( *'78
I In doubL ubouL LIe uccurucy oI LIe bIude ungIe, use u
spIrIL IeveI Lo cIeck LIe drop.
IrsL use LIe IeveI Lo seL LIe bIude rooL verLIcuI (or
IorIzonLuI II you preIer, buL be consIsLenL).
AL eucI sLuLIon, pIuce LIe IeveI uguInsL LIe IeudIng
edge und cIeck LIe drop beLween LIe IeveI und LIe
LruIIIng edge.
WIen meusurIng LIe drop, muke sure LIuL LIe IeveI Is
verLIcuI (or IorIzonLuI II upproprIuLe). I LIe drop Is Loo
Iurge or smuII, udjusL IL by sIuvIng wood Irom LIe
IeudIng or LruIIIng edge us requIred.
;47< 4?977 5#)K.*/ (I% (I.5M*%&&
TIIs LubIe sIows LIe LIIckness oI LIe bIude secLIon.
station thickness
1 1 3/8 36 mm
2 15/16 25 mm
3 1/2 13 mm
4 3/8 10 mm
5 5/16 8 mm
6 1/4 7 mm
AL eucI sLuLIon, meusure LIe upproprIuLe LIIckness
Irom LIe wIndwurd Iuce, und muke u murk. JoIn LIe
murks Lo Iorm u IIne.
Do LIIs uguIn uL LIe LruIIIng edge.
WIere LIe LIIckness runs ouL uL LIe LruIIIng edge,
druw u dIugonuI IIne ucross LIe buck oI LIe workpIece
Lo meeL LIe IIne uL LIe IeudIng edge.
T
I
P
POSITION A
SET THE BLADE
VERTICAL
ON EDGE
T
I
P
POSITION B
SET THE LEVEL AGAINST
THE LEADING EDGE,
AND MEASURE THE DROP
RULER
THICKNESS
REMOVE
THIS PART
UP TO THE
LINE
TRAILING
EDGE
LEADING
EDGE
TRAILING
EDGE
TIP
TRAILING
EDGE
REMOVE
THIS
PART
GUIDE
LINE
GUIDE
LINE
LEADING
EDGE
TIP
STATION MARKS
REMOVE EVERYTHING ABOVE
THIS TRAILING EDGE LINE
KEEP THIS PART
UNTOUCHED
DROP
L
E
A
D
I
N
G

E
D
G
E
MID
LINE
8"[200]
6"[150]
3"
[75]
5"
[125]
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 XB
!'6:H?I"8+(6#(5*JI"J'K
TIese IInes wIII guIde you us you curve LIe secLIon, Lo
ucIIeve LIe correcL LIIckness. Curve LIe buck oI LIe
bIude down Lo LIese IInes.
As you upproucI LIe IInes LIemseIves, you sIouId
begIn Lo cIeck LIe LIIckness wILI cuIIIpers uL eucI
sLuLIon.
BoLI sIdes oI LIe bIude sIouId now be IIuL und puruIIeI Lo
eucI oLIer, excepL uL LIe Inner purL wIere LIIs Is noL
possIbIe, becuuse LIe workpIece Is noL LIIck enougI Lo
uIIow IuII LIIckness ucross LIe wIoIe wIdLI. n LIIs ureu
you need noL worry ubouL LIe purL neurer Lo LIe LuIIIng
edge, buL Lry Lo muke LIe Iuces puruIIeI wIere you cun.
TIe IInuI bIude secLIon wIII onIy be IuII LIIckness uIong u
IIne LIuL runs ubouL o% oI LIe dIsLunce Irom IeudIng Lo
LruIIIng edges.
;47< ,D39 =#)K% (I% 5-)K%$ &I#F% +* (I% H#5M
+L (I% H"#$%
TIe bIude Is neurIy IInIsIed now. TIe ImporLunL
dImensIons, wIdLI, ungIe und LIIckness ure uII seL. L
onIy remuIns Lo gIve creuLe u suILubIe uIrIoII secLIon uL
eucI sLuLIon. I LIIs Is noL done, LIe bIude wIII Iuve very
IIgI drug. TIIs wouId prevenL IL Irom workIng weII uL
IIgI LIp-speed-ruLIo.
TIe IIrsL purL oI LIIs sLep Is Lo muke u IeuLIered LruIIIng
edge. Tuke greuL cure Lo cuL onIy InLo LIe buck oI LIe
bIude. TIIs Is LIe Iuce you jusL cuL ouL In sLep LIree. Do
noL LoucI LIe IronL Iuce. (You curved LIe IronL Iuce In
SLep Two.)
Druw Lwo IInes uIong LIe buck oI LIe bIude, uL boLI
o% und o% wIdLI meusured Irom LIe IeudIng
Lowurd LIe LruIIIng edge. TIe o% IIne Is Lo guIde
you In curvIng LIe IeuLIered LruIIIng edge.
Now curve oII LIe purL sIown IuLcIed, beLween LIe
LruIIIng edge und LIe mIddIe oI LIe bIude wIdLI. TIIs
wIII Iorm LIe correcL ungIe uL LIe LruIIIng edge. WIen
you Iuve IInIsIed, IL sIouId be possIbIe Lo pIuce u
sLruIgIL edge beLween LIIs IIne und LIe LruIIIng edge.
TIe LruIIIng edge sIouId be Iess LIun 1 mm LIIck.
WIen LIIs Is done, LIe bIude Ius Lo be curved InLo u
smooLIIy curvIng sIupe uccordIng Lo LIe secLIon
sIown.
L Is Iurd Lo prescrIbe exucLIy Iow Lo produce LIe curve.
TIe besL descrIpLIon Is sImpIy 'remove uny corners`. As
you remove corners, you wIII produce new corners,
wIIcI In Lurn need Lo be removed. Run your IIngers over
LIe wood IIgILIy Lo IeeI Ior corners. Remove Iess wood
eucI LIme.
Tuke cure noL Lo remove Loo mucI wood. TIe o% IIne
represenLs muxImum LIIckness purL und sIouId noL be
curved down IurLIer. Tuke cure noL Lo produce u corner
uL LIIs LIIckesL poInL.
;47< ,>N7 '&&%2H".*/ (I% )+(+) I-HJ
*%#-3+%&)
PIeces MuLerIuI DIumeLer TIIck
z
dIsks
ExLerIor quuIILy
pIywood
1o IncIes
|zomm|
1Jz"
|1 mm|
q Woodscrews 1 1Jq" |z mm|
":%%0<6 %&( '77%. %7 JKL *(6'((.
I LIe rooLs oI LIe bIudes Iuve noL uIreudy been cuL Lo u
1zo ungIe uIreudy, LIen LIIs Is LIe LIme Lo cuL LIem.
THICKNESS
30%
70%
CHECK FOR THICKNESS
AT 30% CHORD WIDTH
FROM THE LEADING
EDGE
LEADING
EDGE
MAXIMUM
THICKNESS
HERE
THICKNESS
30%
50%
REMOVE
TRAILING
EDGE
MAXIMUM
THICKNESS
HERE
CUT BEVEL
TO HERE
FINISHED
BLADE
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 XD
!'6:H?I"8+(6#(5*JI"J'K
1 3/4"
[44mm]
90
60
120
MID
LINE
Druw u mId-IIne
uL " |; mm|
Irom eucI edge.
Druw u IIne uL
rIgIL ungIes
(qodegrees) Lo
LIe edge, und 1
Jq |qq mm|
uwuy Irom LIe
bIude rooL. TIe
bIude rooL muy
noL be squure.
Be sure LIuL LIIs IIne Is druwn squure.
Druw ungIed IInes connecLIng LIe ends oI LIIs IIne Lo
LIe poInL wIere LIe mId-IIne IILs LIe end us sIown.
TIese Lwo IInes sIouId Lurn ouL Lo be ungIed uL 1zo
degrees Lo LIe edge oI LIe wood.
Suw oII LIe LrIunguIur pIeces Irom LIe corners by
cuLLIng uIong LIe ungIed IInes, IeuvIng u cenLruI 1zo-
degree poInL on LIe bIude rooL. SeL LIe IInes up
verLIcuIIy wIIIe you cuL LIe workpIece.
@)',0<6 )<* *'0$$0<6 %&( 8$2/77* *0.,.
CIoose one dIsk Lo be LIe /%)#-3. Druw u cIrcIe uL LIe
sume dIumeLer us LIe mounLIng
IoIe cenLres.
uy LIe IronL (ouLer) mugneL
roLor onLo LIe dIsk cenLruIIy
und drIII IIve 1Jz" |Iour 1z mm|
IoIes LIrougI LIe dIsk.
CureIuIIy murk LIe dIsk wILI
uny Index murks so LIuL you cun
pIuce IL uguInsL LIe mugneL
roLor In exucLIy LIe sume
posILIon uguIn.
Druw Lwo cIrcIes on LIe dIsk
usIng dIumeLers 6"|1o| und
8"|zoo|.
Use LIe compusses Lo wuIk
uround LIe ouLer cIrcIe murkIng
sIx, equuIIy spuced poInLs.
Use every second poInL Lo druw
u IIne rudIuLIng Irom LIe cenLre.
EucI IIne represenLs LIe mIddIe
oI one bIude Ior LIe purpose oI
murkIng ouL screw IoIes
(noLIIng uccuruLe more LIun
LIuL).
Now seL LIe compusses Ior u 1"
|z mm| rudIus und wuIk LIem
uround LIe ouLer cIrcIe Ior Lwo sLeps Irom LIe IIne In
eucI dIrecLIon, murkIng IIve IoIe cenLres.
Murk unoLIer Iour IoIe cenLres wILI LIe compusses on
LIe Inner cIrcIe In u sImIIur IusIIon buL sLruddIIng LIe
cenLre IIne.
PIuce LIe musLer dIsk on Lop oI
LIe oLIer pIywood one cenLruIIy
und Iuy LIem on some wusLe
wood Ior supporL. DrIII z;
neuLIy spuced screw IoIes
LIrougI boLI dIsks.
CounLersInk LIe screw IoIes
Irom LIe ouLsIdes. ConsIder
wIIcI Iuce wIII meeL LIe mugneL
roLor.
"$)580<6 %&( I$)*(. %76(%&('
uy LIe bIudes ouL on LIe IIoor, wIndwurd Iuce down
(curved Iuces up). IL LIe rooL LogeLIer. Muke equuI
spucIng beLween LIe LIps.
Muke u murk on eucI bIude uL "|1zmm| rudIus Irom
LIe cenLre oI LIe roLor.
MASTER DISK
MATES WITH
FRONT MAGNET
ROTOR
3 " [ 7 5 ]
6"[150]
SAW
3"
[75]
1 1/2"
[37mm]
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 XP
!'6:H?I"8+(6#(5*JI"J'K
PosILIon LIe musLer dIsk cenLruIIy on LIe bIude rooLs by
uIIgnIng LIe dIsk's edges on LIese murks. Screw IL onLo
LIe bIudes wILI q screws per bIude.
Turn LIe ussembIy over und repeuL, usIng LIe oLIer dIsk.
Turn IL buck uguIn. Murk LIe cenLres oI LIe Iour 1Jz" |1z
mm| IoIes by drIIIIng very sIIgILIy LIrougI LIe musLer
dIsk InLo LIe bIudes. Remove LIe musLer dIsk. uy LIe
IronL oI LIe Iub on wusLe wood, und use u J8" |16mm|
drIII Lo IoIIow LIrougI uL LIe sume posILIons. Tuke greuL
cure Lo drIII squure Lo LIe Iuce.
TIese IoIes provIde u cIeurunce IIL Ior LIe 1Jz" |M1z|
sLuds LIuL secure LIe bIude ussembIy Lo LIe uILernuLor.
TIe ussembIy IocuLes precIseIy on LIe musLer dIsk.
Now unscrew LIe IronL dIsk, reudy Ior puInLIng.
;47< ;>O =-((.*/ +-( #*$ /"-.*/ +* (I% G%$/%&
*%#-3+%&)
PIeces MuLerIuI engLI WIdLI TIIck
1 OIIcuLs oI
wood, wILI
sLruIgIL
gruIned
porLIons
EnougI Lo
IInd some
nIce
porLIons
Over "
|;mm|
1 1Jz"
|;
mm|
TIIs dIugrum sIows LIe dImensIons oI LIe wedges. TIe
sImpIesL wuy Lo produce LIem Is Lo cuL LIem Irom LIe
corners oI bIocks oI wood us sIown.
CIoose u cIeur purL oI LIe bIock und druw Lwo IInes uL
rIgIL ungIe Lo LIe corner, sIown dusIed In LIe dIugrum.
Meusure ouL LIe " und LIe 1 1Jz", und druw LIe ungIed
IInes, murkIng LIe cuLs you wIII muke. To cuL ouL LIe
wedges, pIuce LIe bIock oI wood In u vIce wILI one IIne
verLIcuI. AIIgn LIe bIude oI LIe suw cureIuIIy so LIuL IL
IInes up wILI boLI IInes demurcuLIng LIe cuL. TIen suw
ouL LIe wedge.
TIe posILIon Lo gIue LIe wedge on Is sIown In SLep Two.
PuInL LIe bIudes und dIsks beIore IInuI ussembIy.
SANDWICH THE
BLADE ROOTS
BETWEEN TWO
DISKS
SPACE THE BLADE
TIPS AT EQUAL
DISTANCES APART
SCREW EACH DISKS
TO THE BLADES
WITH 9 SCREWS
PER BLADE
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 XQ
!'6:H?I"8+(6#(5*JI"J'K
STATOR
STUD
ROTOR
YAW
BEARING
!"#$%&!#'% #)$'%*
TIe uILernuLor consIsLs oI u sLuLor dIsk sundwIcIed
beLween Lwo mugneL roLors. SLrong mugneLIc IIux pussed
beLween LIe Lwo roLors und LIrougI LIe coIIs In LIe
sLuLor. TIe movemenL oI LIe roLors sweeps LIe IIux
ucross LIe coIIs, producIng uILernuLIng voILuges In LIem.
TIIs secLIonuI vIew
sIows LIe roLuLIng
purLs In bIuck. our
1Jz"|1z mm|
uIILIreud sLuds
|LIreuded rod|
supporL LIe Lwo
mugneL roLors on
LIe Iub IIunge, und
keep LIem uL LIe
correcL spucIng
upurL Irom eucI
oLIer. TIe sume
sLuds ure uIso used
Ior mounLIng LIe
bIudes on LIe IronL
oI LIe uILernuLor.
TIere ure 1z mugneL bIocks
on eucI roLor. We embed
LIe bIocks In u poIyesLer
resIn cusLIng Lo supporL
LIem, und Lo proLecL
LIem Irom corrosIon.
EucI mugneL bIock Ius u
norLI poIe und u souLI poIe. TIe
poIes ure urrunged uILernuLeIy, so norLI Iuces LIe sLuLor
on one bIock und souLI on LIe nexL. TIe poIes on LIe
oLIer mugneL roLor ure urrunged In
LIe opposILe poIurILy, so LIuL norLI
poIes Iuce souLI poIes ucross LIe
sLuLor. n LIIs wuy, u sLrong
mugneLIc IIux Is creuLed LIrougI LIe
sLuLor beLween LIe mugneL roLors.
MugneLIc IIux LruveIs besL LIrougI
sLeeI. TIe roLor dIsks ure mude Irom
LIIck sLeeI pIuLe Lo curry LIe IIux.
BuL LIe mugneLs Iuve Lo work Iurd
Lo pusI IIux ucross LIe gups, becuuse
LIere Is no sLeeI. A wIder gup uIIows
more room Ior u IuLLer sLuLor, buL
weukens LIe IIux.
F&( .%)%7'
TIe sLuLor Is mounLed uL LIree poInLs uround ILs
perIpIery, usIng LIree more 1Jz" |1z mm| sLuds. TIe
coIIs embedded wILIIn IL ure dImensIoned sucI us Lo
encIrcIe LIe IIux Irom one mugneL poIe uL u LIme. As LIe
mugneL bIocks puss u coII, LIe IIux LIrougI LIe coII
uILernuLes In dIrecLIon. TIIs Induces un uILernuLIng
voILuge In eucI Lurn oI LIe coII. TIe voILuge Is
proporLIonuI Lo LIe ruLe oI cIunge oI IIux. VoILuge
LIereIore depends on:
LIe speed oI roLuLIon
LIe densILy oI LIe IIux
LIe number oI Lurns In LIe coII.
TIe number oI Lurns oI wIre In eucI coII Is used Lo
conLroI LIe speed oI LIe wInd LurbIne. I LIe number oI
Lurns Is Iurge, LIen LIe ouLpuL wIII reucI buLLery voILuge
und sLurL Lo cIurge LIe buLLery uL u Iow roLuLIonuI speed
(rpm). I we use Iewer Lurns oI LIIcker wIre In LIe coIIs,
LIen IL wIII need Lo run IusLer. TIe number Is cIosen Lo
suIL LIe roLor bIudes und uIso LIe buLLery voILuge.
TIere ure Len coIIs In LIe sLuLor. TIe LweIve mugneL
poIes puss LIe coIIs uL dIIIerenL LImes. TIIs pIuse Iug
beLween coIIs meuns LIuL LIe Lorque Is mucI smooLIer
LIun IL wouId be II LIere were 1z coIIs. I uII LIe coIIs
were syncIronIsed wILI eucI oLIer (sIngIe pIuse) LIen
LIe mucIIne wouId vIbruLe quILe InLenseIy wIen
producIng power.
G87>+8(56 %:7 &7+8(56 :'&
A wIeeI-beurIng Iub Irom u cur mukes u good beurIng
Ior LIe uILernuLor. n LIe UK, VuuxIuII CuvuIIer reur
beurIng Iubs Irom uround 'B' or 'C' regIsLered veIIcIes
ure IdeuI Ior exumpIe. Remove LIe sLub sIuIL Irom LIe
veIIcIe by removIng Iour screws In LIe reur IIunge. Keep
LIe screws II possIbIe.
THE STATOR
CASTING CONTAINS
TEN COILS
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 XR
!'6:H?I"8+(6#(5*JI"J'K
TIe IeveI oI corrosIon Is
usuuIIy preLLy IIgI buL
LIIs need noL be u worry.
Undo or drIII ouL LIe
smuII reLuInIng screw on
LIe brukedrum. Remove
LIe bruke drum usIng u
Iummer und u Iever.
PrIse oII LIe dusL cover
Irom LIe beurIngs.
Remove LIe spIIL pIn und
undo LIe reLuInIng nuL.
DIsmunLIe LIe beurIngs
und InspecL LIem. I LIey
Iook worn or corroded,
repIuce LIem. TIIs
enLuIIs knockIng ouL LIe
ouLer sIeIIs Irom LIe Iub cusLIng und repIucIng LIem Loo.
BeurIng seLs ure uvuIIubIe Irom moLor purLs IucLors. You
cun dIscurd LIe seuI uL LIe buck oI LIe Iub. L wIII creuLe
Loo mucI IrIcLIon und Is noL necessury.
CIeun uII purLs wILI u rug or puInL brusI und some
gusoIIne |peLroI| or puruIIn. Tuke specIuI cure Lo cIeun
LIe beurIng ruces meLIcuIousIy II you pIun Lo re-use
LIem. WIen LIe LIme comes Ior re-ussembIy oI LIe Iub
Lo LIe sIuIL, greuse LIe oId beurIngs IIgILIy Lo prevenL
excessIve IrIcLIon. TIgILen LIe reLuInIng nuL wILI u
spunner, roLuLe LIe Iub und sIucken LIe nuL uguIn.
TIgILen wILI IIngers und cIeck LIuL LIere Is no sIuck buL
LIe Iub revoIves IreeIy. ock LIe nuL wILI u spIIL pIn und
repIuce LIe dusL cover.
n LIe USA IL muy be eusIer Lo IInd u dIIIerenL Lype oI
wIeeI Iub wILI IIve IoIes In LIe wIeeI. TIe AmerIcun
Iubs mude by GeneruI MoLors Ior LIe CILuLIon, CuvuIIer
und oLIer medIum sIzed curs Ius u wIeeI IIunge wILI IIve
sLuds.
TIe USAJGM Iub Is IIke LIe UK Iub reversed. TIe GM
Iub's wIeeI IIunge Is mounLed on u sIuIL LIuL runs InsIde
u beurIng, ruLIer LIun beIng mounLed on u beurIng LIuL
runs on u sIuIL. ConsequenLIy LIe beurIng Is uL LIe buck
end In LIIs Lype oI Iub. TIe Inbourd end oI LIIs Iub unIL
uIso Ius u IIunge.
A)."".*/ +-( (I% PQRS TPR 22U I+"%& .* (I% L"#*/%
TIe wIeeI IIunge on LIe Iub uIreudy Ius Iour IoIes In IL.
TIe IoIes muy uIso Iuve wIeeI sLuds In LIem. Knock uny
wIeeI sLuds ouL wILI u Iummer. We need Lo enIurge LIe
IoIes Lo 1Jz" |1z mm| dIumeLer. SupporL LIe Iub on u
drIII press so LIuL LIe IIunge Is IeveI, und drIII LIe Iour
IoIes ouL wILI u 1Jz" |1z mm| drIII.
TIe IoIes In LIe sIuIL reur IIunge muy Iuve been Lupped
ouL wILI un unusuuI LIreud. I you sLIII Iuve LIe orIgInuI
screws In usubIe condILIon, LIIs Is noL u probIem. I noL
LIen enIurge LIese IoIes Lo J8" |1o mm|. TIen you cun
use J8" |M1o| boILs und nuLs.
TIe reur IIunge muy Iuve u buIge or projecLIon In LIe
cenLre. L muy be possIbIe Lo grInd LIIs oII. I noL LIen
you wIII Iuve Lo muke u IoIe In LIe mounLIng bruckeL Lo
uccommoduLe LIIs Iump.
ook uIeud Lwo puges Ior u 57:<%0<6 *0)6')5 Ior LIe
GM Iub wILI beurIng IousIng uL LIe reur.
BEARING HUB
AND SHAFT
REAR
VIEW
SECTION
FRONT
VIEW
BEARINGS
1/2" [12 mm]
HOLES AT
4"[100 mm] PCD
WHEEL FLANGE
US TYPE WHEEL BEARING
WITH FIVE HOLES
BEARING
REAR FLANGE
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 XZ
!'6:H?I"8+(6#(5*JI"J'K
Y+&8(I+%(56 %:7 +)%785+%"8
="'5%?
*%#-3+%&)
PIeces MuLerIuI engLI DIumeLer TIIck
1 SLeeI pIpe
z" nomInuI
1z" |oo| z J8"
6o. OD
1J8"
mm
1 SLeeI pIuLe z 1Jz"|6| z 1Jz"|6| J16"
z SLeeI
ungIe
1o 1Jz"
|z6; mm|
or 11 1Jz" Ior
GM Iub
z"
|o mm|
1Jq"
|6 |
z SLeeI ungIe z"
|omm|
z"
|o mm|
1Jq"
|6 |
1 SLeeI ungIe q"
|1oo mm|
z"
|o mm|
1Jq"
|6 |
TIe cenLrepIece oI LIe wInd LurbIne mounLIng Is LIe yuw
beurIng. A 1z" |oo mm| pIece oI z"nomInuI bore pIpe
(6o. mm overuII dIumeLer) wIII be used Ior LIe ouLer
purL oI LIIs beurIng ussembIy. WeId u smuII dIsk onLo LIe
Lop oI LIIs pIpe. An oII-cuL Irom LIe mugneL-pIuLe IoIe-
suw operuLIon Is perIecL. IrsL enIurge LIe cenLruI IoIe Lo
ubouL Jq" |zo mm| Ior wIrIng down LIe LowerJmusL.
Tuke cure Lo weId LIIs Lop pIuLe on squure.
TIe 'yuw beurIng' pIpe wIII sImpIy drop onLo u pIece oI
1." nomInuI bore sLeeI pIpe und roLuLe on IL wILI some
greuse (und muybe u wusIer) beLween LIem. L's sucI u
sImpIe concepL LIuL mosL peopIe cun'L beIIeve IL buL IL
works very weII. n smuII wInd LurbIne desIgn, LIe
sImpIesL soIuLIons ure usuuIIy LIe mosL successIuI und
reIIubIe, us weII us beIng cIeup und eusy.
TIe uILernuLor mounLIng bruckeL consIsLs oI Lwo pIeces
oI z" x z" x 1Jq" |o x o x 6 mm| sLeeI ungIe, eucI
1o 1Jz" |z6; mm| Iong. TIey ure weIded Lo LIe cenLre oI
LIe yuw beurIng ouLer Lube, Lo Iorm u cIunneI InLo wIIcI
LIe reur IIunge oI LIe sIuIL IILs, und Is boILed on. See
nexL puge Ior un
uILernuLIve sLyIe Lo suIL LIe
GM Lype oI Iub Iound In
LIe USA.
TIe ends oI LIe pIeces oI
ungIe wIII need Lo be
sIuped wILI u grInder Lo
LIe curve oI LIe yuw-
beurIng pIpe beIore
weIdIng. NoLe LIuL LIe
curve Is symmeLrIcuI, und
LIe bruckeL LIereIore sILs
cenLruIIy on LIe pIpe In
boLI dIrecLIons. n LIe
cuse oI LIe GM Iub LIe
curve Is usymmeLrIcuI buL
you cun pIuce LIe pIpe over
LIe pIece oI ungIe In LIe correcL posILIon und druw
uround IL.
TIe bruckeL Iuce sIouId be neur verLIcuI (puruIIeI Lo LIe
yuw beurIng). I LIere Is uny LIIL, IL sIouId be sIIgILIy
cIockwIse In LIe ubove sIde-vIew. TIIs wouId Increuse LIe
cIeurunce oI LIe bIude LIps Irom LIe Lower.
PosILIon LIe sIuIL IIunge cenLruIIy beLween LIe upper und
Iower Iuces oI LIe cIunneI, und "|1z mm| uwuy Irom
LIe cenLre oI LIe yuw beurIng. L Is noL eusy Lo meusure
LIIs oIIseL us sucI buL II you meusure LIe sIuIL dIumeLer
us 1J16" |zq mm| (suy) LIen you cun compuLe LIuL LIe
spuce beLween LIe ouLsIde oI LIe yuw pIpe und LIe sIde oI
LIe sIuIL musL be 1Jq" |8 mm|. (1z mm - (6o +
zq)Jz) = 8 mm
Use u suILubIe drIII sIze (J16" |q mm|?) Lo murk LIe
posILIons oI LIe Iour IoIes und LIen drIII LIem ouL J8"
|1o mm| Lo IIL LIe mounLIng boILs.
5"
[125]
3 1/4"
[83 mm]
10 1/2"
[267]
12"
[300]
60
WELDS
ALTERNATOR
MOUNTING BRACKET
4"
[100]
2"
[50]
BEARING HUB
PLAN VIEW
SHAFT
HUB
SIDE VIEW
SECTION
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 XS
!'6:H?I"8+(6#(5*JI"J'K
Mounting diagrams
TIere ure Lwo dIugrums on
LIIs puge Lo sIow LIe Lwo
dIIIerenL Lypes oI Iub. TIe
Lop dIugrum Is Ior LIe UK
CuvuIIer Iub. TIe Iower
one sIows LIe USA
GeneruI MoLors Iub.
TIe beurIng Is uL LIe buck
end In LIe USA Lype oI
Iub. TIe Inbourd end oI
LIIs Iub unIL Ius u IIunge
LIuL you cun use Lo mounL
IL wILIIn LIe cIunneI, buL
LIe beurIng IousIng
projecLs beyond LIIs reur
IIunge. To mounL LIIs unIL
wILIIn LIe supporL bruckeL,
you Iuve Lo cuL u IoIe
ubouL " In dIumeLer
LIrougI LIe bruckeL.
Secure LIe reur IIunge Lo
LIe bruckeL wILI Iour 1Jz"
boILs us sIown In LIe Iower
dIugrum.
TIe sLuLor wIII be mounLed on
LIree 1Jz" sLuds. TIe sLuds In
LIeIr Lurn wIII be supporLed by
LIree Iugs mude Irom z" |o
mm| sLeeI ungIe. TIe IengLIs
oI ungIe requIred ure z"|o|,
z"|o| und q"|1oo mm|. TIe
q" |1oo mm| IengLI needs Lo
be weIded ucross LIe end oI
LIe sIuIL supporL bruckeL
(cIunneI secLIon) descrIbed
ubove. TIe smuIIer bruckeLs
wIII be weIded dIrecLIy Lo LIe
yuw beurIng Lube, Lop und
boLLom.
Stator lug positions
TIe USA mugneL versIon Ius
sIIgILIy dIIIerenL sLuLor
dImensIons Irom LIe UK
meLrIc mugneL versIon. TIe
upper druwIng uppIIes Lo UK
mugneLs, und LIe Iower one Is
Ior z" x 1" USA mugneLs.
2 1/4"
6 "
1 "
2 3/4"
4 1/8"
2 7/8"
1 1/4"
YAW
BEARING
2 "
11 1/2"
ANGLE
BEARING
HUB
1/2" STUD
CENTRE
7 5/8"
5 "
1 1/4"
1/2"
ANGLE
4 "
8 "
1 1/4"
2 1/2"
2 1/2"
FLANGE
0!4 1N ^42N-M. ,-0! 0!4 O@ !13
SIDE VIEW
THERE ARE FIVE STUDS
IN THE FLANGE OF THE
GM HUB
2 "
1 1/4"
6 1/2"
REAR VIEW
TOP VIEW
TOP VIEW
ROTOR
STATOR
ROTOR
1/2" [M12]
STUD
1]^42N-M. ,-0! ^U1_!UTT LU^UT-42 !13
ASSEMBLED ALTERNATOR SHOWING STATOR MOUNTING LUGS
STATOR
MOUNT
BEARING HUB
1 1/4"
[30]
SIDE VIEW
1 1/4"
[30]
3"
[75]
3"
[75]
TOP VIEW
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 XW
!'6:H?I"8+(6#(5*JI"J'K
/8())(56 %:7 =+657% 8"%"8 >)+%7?
TIe mugneL roLors consIsL oI 1z" |oo mm| dIumeLer
dIsks, cuL ouL oI J16" |8 mm| mIId sLeeI pIuLe. 1z
mugneL bIocks wIII be mounLed on eucI mugneL-pIuLe,
und encupsuIuLed In u poIyesLer resIn cusLIng.
TIe sLeeI pIuLes ure LIen mounLed on LIe beurIng Iub In
sucI u wuy LIuL LIe mugneLs Iuce eucI oLIer ucross u
smuII gup. TIe sLuLor wIII be mounLed In LIIs gup.
Once LIe Iub IIunge Ius been drIIIed, IL cun be used us u
guIde Ior drIIIIng LIe IoIe puLLerns In LIe mugneL pIuLes.
TIIs Is more uccuruLe LIun murkIng ouL uII LIe cenLres oI
LIe mugneL-pIuLe IoIes by Iund. L Is ImporLunL LIuL LIe
IoIes uIIgn uccuruLeIy wILI LIe Iub IoIes, or LIe
mounLIng sLuds wIII be squInL (In USA = uskew).
Use u IoIesuw Lo cuL u
cIeurunce IoIe Ior LIe
beurIng sLub on LIe Iub.
A z 1Jz" |6 mm|
IoIesuw Is u good sIze.
TIIs wIII uIIow LIe reur
mugneL-pIuLe Lo sIL IIuL
on LIe Iub IIunge. L Is
uIso useIuI Lo Iuve u
Iurge IoIe In LIe second
mugneL-pIuLe. Keep LIe
oII-cuL dIsks Irom LIe
IoIesuw Ior use In LIe
yuw beurIng und LuII
beurIng.
BoIL LIe beurIng Iub
onLo eucI mugneL-pIuLe
In Lurn und revoIve LIe
beurIng Lo cIeck Ior
correcL cenLrIng. Prop u
ruIer or pIece oI wIre
cIose Lo LIe edge und udjusL LIe posILIon unLII LIe pIuLe
runs Lrue. TIgILen LIe cIumps und drIII IoIes LIrougI
LIe IIunge IoIes und InLo LIe pIuLe. IL u boIL InLo eucI
IoIe us you go und re-cIeck LIe cenLrIng. Muke un Index
murk Lo record LIe posILIon oI LIe dIsk on LIe Iub Ior
IuLure reIerence durIng ussembIy. DrIIIIng un Index IoIe
LIrougI LIe Iub IIunge und boLI dIsks Is u good wuy Lo
keep Lruck oI LIe posILIons. Murk LIe Iuces oI LIe dIsk Ior
correcL reussembIy.
RepeuL LIIs operuLIon usIng LIe IronL pIuLe. InuIIy drIII
Lwo J8" |1o mm| IoIes In LIe IronL pIuLe on LIe sume
cIrcIe us LIe 1z-mm IoIes, buL mIdwuy beLween LIem.
Tup LIese IoIes ouL wILI 1Jz" LIreud |M1z|. TIese IoIes
wIII be used Lo juck LIe IonL pIuLe on und oII LIe
uILernuLor usIng Iong 1Jz" |M1z| screws. TIIs Is
necessury becuuse LIe Iorces puIIIng LIe mugneL roLors
LogeLIer wIII be very Iurge wIen LIe mugneL bIocks Iuve
been udded Lo LIem.
Remove uny burr Irom LIe edges oI uII LIe IoIes. TIe
mugneL-pIuLes ure now uImosL reudy Ior resIn cusLIng.
(See 'CusLIng LIe roLors'). Sund LIem uL LIe IusL mInuLe.
@+K(56 %:7 I"() #(5*78
*%#-3+%&)
PIeces MuLerIuI engLI WIdLI TIIck
PIywood q"
|1oo mm|
Over "
|;mm|
1Jz"
|1 mm|
q NuIIs q"
|1oo mm|
J16"
| mm|
1 SLud or
boIL
6" upprox.
|1o mm|
J8"
|1o mm|
NuLs und
wusIers
J8"
|1o mm|
Muke u coII-wIndIng mucIIne Irom pIeces oI 1Jz" |1
mm| pIywood mounLed on u J8" |1o mm| boIL or
uIILIreud sLud. orm LIe coII on Iour pIns mude Irom
Iour-IncI nuIIs cuL oII sIorL.
2. 5 6 8 1 2 12. 5
MAGNET BLOCK
2" X 1" X 1/2"
GRADE 35
NdFeB
46
30
MAGNET
10 THICK
CASTINGOD
310
STEEL
DISKOD
300
MAGNET ID
208
HUBHOLE
65
12
HOLE
CASTING
ID 158
RESIN
CASTING
STEEL
PLATE
GRADE 40 NdFeB
FRONTAL VIEWS OF MAGNET ROTORS FOR THE TWO VERSIONS
REAR STEEL PLATE
1/2"
[12 mm]
HOLE
12"
[300 mm]
DIAMETER
5/16"
[8 mm]
THICK
2 1/2"
[65 mm]
HOLE
FRONT STEEL PLATE
1/2"
[M12]
TAPPED
HOLES
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 BC
!'6:H?I"8+(6#(5*JI"J'K
TIe sIdes oI LIe coIIs
ure supporLed by Lwo
cIeek-pIeces, IeId 1Jz"
|1 mm| upurL by u
cenLruI spucer.
EucI cIeek pIece Ius
deep noLcIes In
opposILe sIdes, Lo uIIow
you Lo sIIp u pIece oI
Lupe uround LIe
IInIsIed coII. TIe Lupe
wIII IoId LIe coII
LogeLIer wIen you
remove IL Irom LIe
wIndIng mucIIne.
IL u IundIe Lo one oI
LIe cIeek pIeces. You
cun use u smuII boIL
curryIng u pIece oI pIpe
Ior comIorLubIe
IundIIng. TIe Ieud oI
LIe boIL musL be sunk
InLo LIe wuII oI LIe
cIeek pIece Lo prevenL
IL Irom cuLcIIng on LIe
wIres.
TIe posILIons oI LIe
IoIes Ior LIe nuIIs wIII
depend on LIe mugneL
sIupe. TIe Lop druwIng
Is Ior LIe USA versIon
wILI z" x 1" mugneL
bIocks. NoLe LIuL LIe
spucer Ius Lo be
LrImmed uL LIe ends Lo
cIeur LIe nuIIs. Tuke
cure Lo drIII LIe IoIes
squureIy InLo LIe
cIeeks.
L's u good Ideu Lo
cIumIer LIe corners oI
LIe cIeek pIeces sIIgILIy on LIe InsIde. TIIs prevenLs LIe
wIre Irom cuLcIIng on LIe corners us LIe wIndIng
mucIIne revoIves.
TIe J8 |M1o| boIL Is used us un uxIe. L rIdes In u IoIe
LIrougI u pIece oI wood. L muy Lurn more IreeIy II LIe
IoIe Is IIned wILI u busI oI some sorL - muybe u meLuI
pIpe. TIgILen LIe nuLs on LIe cIeek pIeces buL noL on LIe
supporLIng beurIng.
,(5*(56 %:7 I"()?
CIoose your wIre Lo suIL LIe mugneL sIze und buLLery
voILuge. MeLrIc sIzes ure suILubIe Ior meLrIc mugneL
bIocks.
*%#-3+%&)
WeIgIL MuLerIuI Turns per coII & sIze VoILuge
8o Lurns oI #1 wIre
|qo Lurns oI 1.q mm|
1z V
16o Lurns oI #18 wIre
|18o Lurns oI 1 mm|
zqV
6 Ibs.
| kg|
Ior Len
coIIs
EnumeI
wIndIng
wIre, cuIIed
mugneL wIre
zo Lurns oI #z1 wIre
|6o Lurns o.; mm|
q8V
BuIId u sLund Ior LIe reeI
oI copper wIndIng wIre.
Tuke cure Lo keep LIe
wIre sLruIgIL. AvoId
bendIng IL unnecessurIIy
or scrupIng In LIe
enumeI. AIIgn LIe coII
wInder Lo LIe reeI sLund,
so LIuL LIe wIre cun Ieed
InLo IL puruIIeI Lo LIe
cIeek pIeces.
Muke u LIgIL qo-degree bend ubouL q" |1oo mm| Irom
LIe end oI LIe wIre und pIuce IL InLo LIe coII wInder, In u
noLcI In LIe ouLer cIeek pIece. Tuck LIe wIre In cIose
uguInsL LIe cIeek pIece. WInd LIe LuII oI wIre uround LIe
J8"|M1o| nuL, sucI LIuL IL cunnoL sIIp oII.
Now grusp LIe
IncomIng wIre wILI
one Iund. WInd LIe
IundIe wILI LIe
oLIer Iund,
counLIng LIe Lurns
us you go. Use LIe
IIrsL Iund Lo keep u
genLIe LensIon In LIe wIre, und Lo conLroI Iow IL IIes In
LIe wInder. uy LIe Lurns oI wIre LogeLIer snugIy, und
buIId LIe coII Lurns up In neuL Iuyers. Work Irom one
sIde gruduuIIy ucross Lo LIe oLIer und gruduuIIy buck. Do
noL uIIow LIe wIre Lo 'wunder Lo und Iro' Irom sIde Lo sIde
or LIe coII wIII noL be ubIe Lo uccommoduLe LIe necessury
number oI Lurns.
WIen you Iuve LIe
rIgIL number oI
Lurns oI wIre on LIe
wInder, IL Is LIme Lo
Lupe LIe coII. Do noL
reIeuse LIe LensIon
In LIe wIre unLII IL Is
secureIy Luped.
SIIde LIe end oI u
pIece oI Lupe under
LIe coII usIng LIe
WIRE REEL HOLDER
2 x 1
2.5
3.5
COIL LEG IS
3/4 WIDE
1. 5"
1. 5"
1 "
3/8 [10]
HOLE
1/2' [13] THICK
PLYWOOD
CHEEK PIECE (TWO OFF)
FOUR HOLES 3/16" [5]
3" [75mm]
4"
[100 mm]
[37.5]
[25]
[37.5]
3/8"
[M10]
H SHAPED CHEEK PIECES
WINDING
HANDLE
PIPE
EMBEDDED
IN WOOD
IS USED AS
BEARING
BUSH
STEEL PINS
(SAWN OFF
4" NAILS)
8"
[208]
SPACER
2" X 3/4"
13/16"
1+13/16"
HOLE LOCATIONS
1/2" THICK
SPACER
46 x 20 mm
25mm
41 mm
HOLE LOCATIONS
13 mm THICK
UK VERSION
USA VERSION
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 BX
!'6:H?I"8+(6#(5*JI"J'K
noLcI und wrup IL secureIy. Do LIe sume on boLI sIdes
beIore you reIeuse LIe LensIon.
CIeck LIuL LIe dImensIons oI LIe coII ure us sIown.
RepeuL LIIs process unLII you Iuve Len coIIs.
I In doubL ubouL LIe number oI Lurns, weIgI eucI coII
und compure LIem. SmuII errors ure noL sIgnIIIcunL buL
LIe weIgILs sIouId be LIe sume wILIIn % or so uL worsL.
TIe Len coIIs wIII be IuId ouL In u cIrcIe Lo muLcI LIe
mugneL bIocks. TIe spucIng beLween LIe Inner edges oI
LIe IoIes wIII be 8 IncIes, or zo8 mm Ior LIe meLrIc
mugneLs, us sIown.
$"$+#%,+!" #)$'%*
TIe eIecLrIcuI ouLpuL oI LIe wInd LurbIne cun be
meusured us u voILuge und u currenL. VoILuge Is
'eIecLrIcuI pressure' und Is usuuIIy consLunL Ior u
purLIcuIur suppIy (Ience 1z-voIL or zqo-voIL suppIy).
You cun meusure LIe voILuge oI u suppIy wILI u muILI-
meLer. ToucI LIe Lwo probes oI LIe meLer Lo LIe Lwo
wIres Irom LIe suppIy und reud ouL LIe voILuge.
CurrenL In eIecLrIc cIrcuILs cun uIso be meusured.
CurrenL In 'umps' normuIIy vurIes sIowIy Irom zero Lo
some IIgI vuIue und buck, us LIme goes by und
condILIons cIunge. WIen currenL IIows In eIecLrIcuI
cIrcuILs, LIen power Is beIng LrunsmILLed Irom LIe
suppIy Lo LIe 'Ioud'.
TIIs dIugrum
sIows Lwo sorLs
oI ummeLer.
One Is
unuIogue, und
LIe oLIer Is u
dIgILuI cIump-
meLer. n boLI
cuses LIe
currenL pusses
LIrougI LIe
meLer In some
wuy.
Here LIe suppIy Is u buLLery und LIe Ioud Is u buIb. TIe
suppIy cun be u wInd LurbIne und LIe Ioud cun be u
buLLery. n eILIer cuse LIe power LrunsmILLed Is
meusured In 'wuLLs'. Power ouLpuL Is cuIcuIuLed by
muILIpIyIng LIe voILuge by LIe currenL. or exumpIe u
zo-ump currenL In u 1z-voIL cIrcuIL deIIvers zqo wuLLs.
TIere ure Lwo Lypes oI suppIy, AC und DC. BuLLerIes
uIwuys provIde DIrecL CurrenL (DC). DC Is consLunL In ILs
poIurILy und mugnILude over LIme. One wIre Is Lermed
'posILIve' und LIe oLIer 'neguLIve'.
TIe muIns grId on LIe oLIer Iund suppIIes AILernuLIng
CurrenL (AC). n LIe cuse oI un AC suppIy, LIe poIurILy
reverses consLunLIy, muny LImes eucI second, und LIe
mugnILude rIses und IuIIs In u 'wuveIorm'. AC cun be
converLed Lo DC usIng u recLIIIer, consIsLIng oI u number
oI one-wuy juncLIons cuIIed 'dIodes'.
You cun use u muILImeLer Lo meusure AC voILuge, buL you
need Lo cIunge LIe seIecLor swILcI Lo ACV. TIe voILuge
dIspIuyed wIII be u sorL oI 'uveruge' vuIue oI LIe
consLunLIy vuryIng IeveI.
TIe uILernuLor In our wInd LurbIne produces -pIuse AC.
TIIs meuns LIuL LIe voILuges Irom LIe coIIs ure rIsIng und
IuIIIng uL dIIIerenL LImes Irom eucI oLIer. Here Is u
grupI, sIowIng Iow LIe voILuges vury over LIme.
We connecL LIe coIIs In 'sLur'
conIIguruLIon, wILI uII LIe sLurLs
LogeLIer und LIe AC ouLpuL Luken
Irom LIe IInIsI LuIIs. ConnecLIng
LIese LuIIs Lo u recLIIIer converLs
LIe AC InLo DC by onIy uIIowIng
LIe currenL Lo IIow In one dIrecLIon
LIrougI LIe DC ouLpuL cIrcuIL.
TIe voILuge produced by LIe coIIs
wIII depend on boLI LIe speed oI
roLuLIon (see 'AILernuLor TIeory')
und uIso on LIe currenL suppIIed by
LIe uILernuLor. Some voILuge Is IosL
InLernuIIy wIen LIere Is currenL
LIrougI LIe coIIs.
DCV
10
MULTIMETER
BULB 12.36
battery
BULB
battery
A
2.05
5-phase AC voltage
time axis
START FINISH
START FINISH
COIL CONNECTIONS
RECTIFIER
COIL
COIL
EACH DIODE ALLOWS CURRENT TO FLOW
ONLY IN THE DIRECTION OF THE ARROW
START FINISH
START FINISH
COIL
COIL
START FINISH
START FINISH
COIL
COIL
START FINISH
START FINISH
COIL
COIL
START FINISH
START FINISH
COIL
COIL
+
-
OUTPUT
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 BB
!'6:H?I"8+(6#(5*JI"J'K
L"557I%(56 %:7 I"()?
*%#-3+%&)
IengLI MuLerIuI SIze VoILuge
#1q |z mm|
or sImIIur
1z-V o'
|1o m|
IexIbIe wIre
wILI IIgI
LemperuLure
InsuIuLIon
#18 |o. mm|
or sImIIur
zq-V or
q8-v
' |1 m| ResIn cored
soIder wIre
' |1 m| nsuIuLIon
sIeevIng
urge enougI Lo IIL
over LIe joInLs
?.*(& L+) &+"$%).*/
Use u cIeun soIderIng Iron und mukes sure IL Is IoL beIore
you sLurL. ToucI some soIder wIre onLo LIe LIp oI LIe
Iron und IL sIouId meIL on InsLunLIy.
TwIsL LIe wIres LogeLIer In u joInL und pIuce LIe LIp oI LIe
Iron uguInsL LIIs joInL so us Lo ucIIeve muxImum conLucL
ureu. WuIL u second or Lwo und LIen Ieed soIder wIre
InLo LIe poInL oI conLucL beLween Iron und joInL. TIe
soIder sIouId meIL InLo LIe joInL und ussIsL wILI curryIng
IeuL IurLIer InLo LIe joInL. GIve IL LIme. Keep LIe Iron
LIere unLII LIe joInL Is IuII oI soIder und LIen remove.
Tuke cure noL Lo dIsLurb LIe joInL unLII LIe soIder seLs (z
seconds). Never Lry Lo udd soIder Lo u joInL Irom LIe
Iron. TIe soIder musL come Irom LIe reeI oI soIder wIre.
TIe resIn core In LIe wIre IeIps LIe soIder Lo IIow InLo
LIe joInL.
;+"$%).*/ (I% 5+." (#."&
TIe copper wIndIng-wIre Ius enumeI couLIng wIIcI
InsuIuLes IL Irom ILs neIgIbours In
LIe coII. BeIore soIderIng LIe ends
onLo IIexIbIe LuIIs, you musL cIeun
LIIs enumeI oII u sIorL IengLI.
Scrupe Jq" |zomm| oI LIe couLIng
oII LIe end oI LIe wIre wILI u sIurp
knIIe or sundpuper. Use LIe
soIderIng Iron und some soIder Lo
couL or 'LIn' LIe end oI LIe wIre wILI
soIder. TwIsL LIe IIex uround LIe
LInned wIre or pIuce LIem sIde-by-
sIde, bInd LIem wILI u LIIn sLrund
oI copper. TIen soIder LIem
LogeLIer. SIIp some InsuIuLIon
sIeevIng over LIe joInL.
uy LIe coIIs In LIe sLuLor mouId us
sIown beIow. TIey uII Iuve Lo be
exucLIy LIe sume In orIenLuLIon,
wILI LIe sLurLIng LuII on Lop. L
does noL muLLer II your coIIs ure u
mIrror Imuge oI LIe ones sIown so Iong us LIey ure uII
LIe sume.
4I% ).*/ *%-()#"
Tuke u pIece oI IIexIbIe sLrunded InsuIuLed wIre (IIex),
und muke u Ioop LIuL IILs snugIy uround LIe ouLsIde oI
LIe coIIs In u rIng. TIe Ioop wIII resL uguInsL LIe ouLer
edges oI LIe coIIs In sucI u wuy us Lo IoId LIem In,
uguInsL eucI oLIer In LIe desIred posILIon.
(See "wIndIng LIe coIIs" Ior correcL spucIng oI 8" |zo8
mm|). TIere sIouId be ubouL J16" | mm| beLween LIe
InsIde oI LIe coIIs und LIe cenLruI dIsk.
BeIore soIderIng LIe
InsuIuLed IIex IInuIIy
InLo u Ioop, cuL Len
IengLIs oI sIeevIng 1
1Jz" |o mm| Iong, und
LIreud LIem uII onLo
LIe Ioop. SLrIp ubouL
1Jz" |1 mm| oI
InsuIuLIon oII LIe IIex uL
equuI InLervuIs, Lo uIIow
soIdered connecLIons uL
eucI coII us sIown.
TIen soIder LIe ends oI
LIe IIex LogeLIer so LIe
Ioop IILs uround LIe Len
coIIs wILI no sIuck.
TIIs Ioop oI IIexIbIe
wIre Is LIe 'rIng neuLruI'
connecLIng uII LIe sLurLs
LogeLIer. L wIII Iuve
no dIrecL connecLIon Lo
unyLIIng eIse.
RING
NEUTRAL
SOLDERED
CONNECTION
EXIT
HOLE
EXIT
HOLE
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 BD
!'6:H?I"8+(6#(5*JI"J'K
4I% +-(F-( G.).*/
TIe IInIsIes oI LIe coIIs provIde LIe ouLpuL Lo LIe
recLIIIer. EucI IInIsI wIre needs u LuII oI IIex soIdered Lo
IL. TIe LuIIs ure LIen brougIL ouL LIrougI LIe Lwo IoIes
In LIe mouId. TIe second dIugrum sIows LIe ouLpuL
LuIIs wILIouL sIowIng LIe rIng neuLruI. L uIso sIows LIe
posILIons wIere LIe mounLIng IoIes wIII be drIIIed.
Tuke cure Lo muke LIe LuIIs Iong enougI Lo reucI LIe
recLIIIer. Use cubIe LIes Lo secure LIe IIex wIrIng LogeLIer
neuLIy. Ensure LIuL LIey ure secured uwuy Irom LIe
posILIons oI LIe mounLIng IoIes or LIey couId be
dumuged durIng LIe drIIIIng oI LIese IoIes.
WIen LIe wIrIng Is compIeLe, cureIuIIy sIIde LIe coII
ussembIy Irom LIe sLuLor mouId und pIuce IL on u IIuL
sIeeL oI bourd. You cun sIIde IL InLo pIuce In LIe cusLIng
wIen LIe LIme comes.
@+K(56 %:7 ?%+%"8 ="')*
*%#-3+%&)
PIeces MuLerIuI engLI WIdLI TIIck
1 PIywood zq" |6oo| zq" |6oo| 1Jz" |1
z SmooLI Iuced
bourd
zq"
|6oo|
zq"
|6oo|
Jq" |1q|
suggesLed sI
SIIIcone seuIunL
Wux poIIsI
1Jq" |6mm| x 1 1Jz" |mm| BoILs
1o Screws
TIe Len coIIs sIouId IIL neuLIy InLo u IIuL mouId, wIere
LIey wIII be encupsuIuLed In poIyesLer resIn Lo Iorm LIe
sLuLor. TIe sLuLor wIII Iuve u IoIe In LIe mIddIe LIrougI
wIIcI LIe Iour roLor-supporLIng sLuds wIII puss. AL LIe
perIpIery IL wIII Iuve LIree Iugs wIere IL Is Lo be
supporLed by 1Jz"|M1z| sLuInIess
uIILIreud sLuds.
B#)M +-( (I% &I#F% +L (I% &(#(+)J
O)- #5- /-#3+, 4+N.3-) 4"3 #5-
/-#3+, /%N!-#)
SLurL wILI % <+-,- "4 789PQ7= //R
<&('""; %<<3"2+/%#-&( 9EPQG@@R
)S.%3-.
Druw M-3#+,%& %!; 5"3+T"!#%&
cenLre-IInes, uL exucLIy qo degrees, und un
"44)-# M-3#+,%& &+!- BP Q79B //R #"
#5- 3+N5# oI LIe verLIcuI IIne.
Druw Lwo cIrcIes on LIe InLersecLIon
oI LIe cenLre IInes. U5- 3%;+.) 4"3 #5-
+!!-3 ,+3,&- +) =PQKH //R %!; #5-
".#-3 ,+3,&- +) KV=8WPQ7H@R.
I you Iuve no compusses bIg enougI,
LIen u sLrIp oI pIywood wIII oILen work
besL. DrIII u IoIe Ior u pencII uL one poInL,
und screw u wood-screw LIrougI uL
unoLIer poInL spuced uL LIe correcL
rudIus.
Murk LIe /".!#+!N:5"&- ,-!#3-)
KVB8WP Q7HGR %'%( 43"/ #5- ,-!#3-.
Murk Lwo cenLres on LIe oIIseL IIne. TIe
sepuruLIon sIouId be 11+1Jz"|oo mm|. Murk LIe
LIIrd IoIe's cenLre on LIe IorIzonLuI cenLre-IIne,
opposILe LIe oIIseL IIne. Do noL drIII uny IoIes yeL!
Druw %3,) "! #5-)- #53-- 5"&-:,-!#3-) %#
7V78EP Q=@ //R 3%;+.). TIese descrIbe LIe
7+3/8
5
11. 5
7+5/8
CENTRE
LINE
24" SQUARE PIECE OF 1/2" PLYWOOD
CENTRE
LINE
STATOR MOULD
6"
DIAMETER
HOLE
7+5/8
EXIT
EXIT
[125]
[190]
[196]
[190]
[300]
[158]
[600] [13mm]
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 BP
!'6:H?I"8+(6#(5*JI"J'K
ouLsIdes oI LIe mounLIng Iugs. InuIIy use u ruIer Lo
connecL LIe bIg cIrcIe Lo LIese new urcs wILI
LungenLIuI IInes so LIuL LIe ouLsIde edge oI LIe sLuLor
Is u smooLI sIupe. C" !"# ,.# #5- /".&; ".#
(-#.
;#*$G.5I.*/ (I% &(#(+) 2+-"$.
WIIIe beIng cusL, LIe sLuLor wIII be sundwIcIed beLween
Lwo smooLI-Iuced bourds: u buse und u IId. DIscurded
kILcIen cubIneLs or workLops ure good Ior LIIs purpose,
or you cun use LIIck composILe bourd Ior sLrengLI, und
udd smooLI Iurdbourd Ior LIe IInIsI.
1#%,X LIe LIree bourds on Lop oI eucI oLIer. TIe
smooLI Iuces oI LIe IId und LIe buse need Lo be In
conLucL wILI LIe mouId pIywood.
C3+&& LIree IocuLIng IoIes LIrougI LIe sLuck so LIuL
you wIII be ubIe Lo reussembIe LIe sundwIcI
uccuruLeIy. TIIs wIII IeIp you geL LIIngs In LIe rIgIL
pIuces. IL eucI IoIe wILI u suILubIe boIL (suy 1Jq"
|6mm|).
*%3X LIe bourds Ior correcL reussembIy - IId, mouId,
buse - Lops und boLLoms IubeIIed cIeurIy.
IL LIe mouId Lo LIe
undersIde oI LIe IId, und
;3+&& #53".N5 LIe surround
InLo LIe IId wILI pIenLIIuI
J16" | mm| IoIes Ior IuLer
use by cIumpIng screws.
Spuce LIese IoIes ubouL 1"
|z mm| uwuy Irom LIe IInes.
You wIII IuLer be ubIe Lo screw LIe
IId down Iurd Lo LIe buse und squeeze LIe cusLIng
LIIckness Lo u mInImum.
=-( +-( (I% &(#(+) &I#F% .* F"1G++$J
Use u jIgsuw Lo ,.# ".# #5- )#%#"3 /".&; by
IoIIowIng LIe Inner cIrcIe und LIen LIe ouLer sIupe
IncIudIng LIe Iugs. L muy be necessury Lo drIII enLry
IoIes Lo geL LIe suw bIude LIrougI LIe pIywood.
DrIII uny sucI IoIes ouLsIde LIe Inner cIrcIe und
InsIde LIe ouLer sIupe.
TIe cenLruI IsIund und ouLer surround wIII boLI be used
IuLer Ior mouIdIng LIe poIyesLer resIn cusLIng. TIeIr
edges sIouId be us smooLI us possIbIe. I LIey Iuve
cuvILIes LIen IIII LIem und sund LIe surIuce smooLI.
TIe sLuLor-sIuped pIece IeIL over (wILI LIe mounLIng
IoIe murks) wIII be LIe exucL sIupe oI LIe IInIsIed sLuLor.
L wIII come In useIuI us u dummy wIen drIIIIng LIe
mounLIng IoIes InLo LIe supporLIng Iugs und In LIe sLuLor
cusLIng ILseII.
C.).*/ %V.( I+"%&
RepIuce LIe surround onLo LIe IId, und ;3+&& #'"
=8EP 5"&-) In LIe IId Lo uIIow Ior LIe wIrIng Lo
emerge Irom LIe mouId. TIese exIL IoIes wIII IIood
wILI resIn. I you cun Iorm LIem InLo u smooLI
conIcuI sIupe (perIups usIng u Lupered reumer),
LIen LIIs wIII IucIIILuLe removuI oI LIe IId wILIouL
dumuge Lo LIe wIrIng. TIe wIrIng wIII emerge rIgIL
uL LIe sLuLor edge, weII cIeur oI LIe mugneL roLor
edge. recommend posILIonIng LIese IoIes' cenLres
ubouL 1+1Jz"|o mm| uwuy Irom, und Lo LIe IeIL oI
LIe rIgIL Iund mounLIng IoIes.
;5)%G (I% 2+-"$ (+ .(& H#&%
PIuce LIe mouId surround onLo LIe buse correcLIy
und ),3-' +# ;"'!Y usIng dIIIerenL IoIes (noL LIe
ones you drIIIed LIrougI LIe IId). Use LIe IId IoIes
Lo posILIon LIe cenLruI IsIund on LIe buse und LIen
screw LIuL down Loo. Cover LIe screw Ieuds wILI
poIIsI undJor Lupe Lo prevenL IIoodIng wILI resIn.
Z<<&( % 4+&&-# "4 )+&+,"!- )-%&%!# Lo LIe Inner
corners, und poIIsI uII exposed surIuces oI LIe
mouId: surround, IsIund, IId und buse generousIy so
LIuL LIe poIyesLer resIn wIII reIeuse. AppIy pIenLy oI
poIIsI Lo LIe wIrIng-exIL IoIes. Run u LIIn beud oI
sIIIcone uround LIe rIms oI LIe surround und IsIund
Lo counLerucL resIn Ieukuge.

LID
MOULD
BASE
LOCATING HOLES
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 BQ
!'6:H?I"8+(6#(5*JI"J'K
L+?%(56 %:7 ?%+%"8
*%#-3+%&)
[.%!#+#( *%#-3+%&
Ibs
|1.q kg|
PoIyesLer resIn (premIxed wILI ucceIeruLor)
cusLIng resIn or IIbregIuss resIn In IIquId
Iorm. PeroxIde cuLuIysL Lo suIL.
z. Ibs.
|1.z kg|
TuIcum powder
' x 18"
|1 x . m|
IbregIuss cIoLI or cIopped sLrund muL
(1 ounce per sq. IooL) or |oog per sq. meLre|
zo Wood screws 1 1Jq" |o mm|
BeIore you sLurL, reud LIrougI LIe InsLrucLIons und be
sure you Iuve everyLIIng Lo Iund IncIudIng resIn, LuIcum
powder, puInL brusI, IIbregIuss cIoLI, coIIs pre-wIred,
und screws Lo cIump LIe mouId LogeLIer.
CuL Lwo sIeeLs oI IIbregIuss
cIoLI (or 'cIopped sLrund muL'
wIII do) Lo IIL InsIde LIe
mouId. You cun use LIe oII-
cuL pIece oI 1Jz' |1 mm|
pIywood us u LempIuLe Ior LIe
cIoLI. Murk LIe sIupe wILI u
IeIL pen und LIen cuL sIIgILIy
InsIde LIe IIne so LIuL your
cIoLI wIII IIe In LIe mouId
comIorLubIy. Muke provIsIon Ior LIe wIres wIere LIey
exIL LIe mouId. Some smuII exLru pIeces oI cIoLI cun uIso
be useIuI Ior sLrengLIenIng LIe Iugs (see IuLer).
A)1 )-*
Go LIrougI LIe process oI ussembIIng LIe sLuLor us u dry
run '+#5".# 3-)+! jusL Lo cIeck LIuL everyLIIng IILs und
LIere wIII be no IoId-ups wIen LIe resIn Is goIng InLo LIe
mouId.
<-((.*/ .( (+/%(I%)
WIen uII Is prepured, you cun geL ouL LIe poIyesLer resIn
und sLurL LIe job. Weur IuLex gIoves Lo proLecL your skIn.
Tuke greuL cure noL Lo spIusI resIn In your eyes. TIIs job
sIouId be done In u weII-venLIIuLed ureu Lo dIsperse LIe
soIvenL Iumes. Cover LIe workbencI wILI newspuper Lo
proLecL uguInsL spIIL or overIIowIng resIn.
*+2 1JzIb |zoo grums| oI resIn wILI 1Jz Leuspoon |
cc| oI cuLuIysL. Use no LuIcum powder uL IIrsL. You
cun use pIgmenL II desIred. MIx very LIorougIIy buL
Lry Lo uvoId sLIrrIng In Loo mucI uIr. Use LIe mIxed
resIn ImmedIuLeIy. I you deIuy u Iew mInuLes IL muy
IeuL up In LIe poL, und become useIess.
\%+!# some oI LIIs resIn mIxLure onLo LIe Iower
surIuce oI LIe mouId. Do noL puInL so vIgorousIy LIuL
you remove LIe poIIsI. uy one sIeeL oI IIbregIuss
cIoLI onLo LIe puInLed surIuce, und suLuruLe IL wILI
more resIn. Use u 'pokIng' moLIon oI LIe brusI Lo
remove uIr bubbIes.
1&+;- LIe pre-wIred coIIs InLo pIuce, mukIng sure LIe
wIres ure posILIoned correcLIy Ior LIe exIL IoIes In LIe
IId.
\".3 LIe remuIns oI LIe IIquId resIn mIx over LIe
copper coIIs so LIuL IL souks In beLween LIe wIres.
Prepure %!"#5-3 3-)+! 0%#,5 In LIe sume
conLuIner, usIng 1 Ib. |qoo grums| oI resIn und 1.
Lsp. |6 cc| oI cuLuIysL. MIx LIe cuLuIysL In cureIuIIy,
und LIen udd ubouL 11 Ib. |qoo grums| oI #%&,./
<"';-3. MIx uguIn.
\".3 #5+) /+2 In beLween LIe coIIs und uround LIe
edge.
>%!N #5- /".&; Lo encouruge uIr bubbIes Lo rIse.
Add pIeces oI IIbregIuss Lo LIe Iugs Ior
reInIorcemenL, und poke LIem Lo dIsIodge bubbIes.
Z;; 4.3#5-3 3-)+!8#%&,./ <"';-3 /+2-) unLII
LIe mouId Is IuII Lo LIe brIm.
AppIy LIe )-,"!; )5--# oI IIbregIuss cIoLI. PuInL
resIn onLo LIe Lop surIuce oI LIe cIoLI. Poke IL Lo
remove bubbIes. CIeun LIe puInLbrusI beIore LIe
resIn seLs.
\&%,- #5- &+; onLo LIe mouId, cureIuIIy LIreudIng
LIe wIrIng LIrougI LIe Lwo IoIes us you do so. Screw
LIe IId down IIrmIy. WIpe up uny resIn overIIowIng
Irom LIe cusLIng. Tuke cure LIuL LIe screw Ieuds do
noL IIII wILI resIn, mukIng IL Iurd Lo remove LIem
IuLer. You cun IIII LIem wILI poIIsI, greuse or
sIIIcone us u proLecLIon.
*"< .< resIn seepIng ouL Irom LIe mouId uL LIe
edges und LIrougI LIe wIrIng exILs. U+N5#-! LIe
screws uguIn.
Keep LIe mouId In u wurm pIuce Ior u Iew Iours. I LIe
resIn sIows no sIgns oI seLLIng, LIen IeuL LIe mouId In
IronL oI u rudIunL IIre Ior u Iew mInuLes Lo kIck-sLurL LIe
reucLIon. L Is normuI Ior LIe resIn cusLIng Lo IeuL up
sIIgILIy once LIe resIn begIns Lo cure.

200g
RESIN
CATALYST
3CC
400g
TALCUM
POWDER
200g
SHAPE OF
CLOTH
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 BR
!'6:H?I"8+(6#(5*JI"J'K
9%2+K.*/ (I% 5#&(.*/ L)+2 (I% 2+-"$
WIen LIe resIn Is IuIIy Iurdened, you cun dIsmunLIe LIe
mouId. Remove uII LIe screws. PrIse LIe Iuyers oI bourd
upurL In severuI pIuces. Use Iummer bIows Lo breuk LIe
bond beLween LIe bourds und LIe cusLIng. Tuke specIuI
cure In LIe ureu oI LIe wIrIng exIL IoIes Lo uvoId
dumugIng LIe InsuIuLIon oI LIe IIexIbIe LuIIs.
0:7 =+657%9>"?(%("5(56 [(6
*%#-3+%&)
PIeces MuLerIuI engLI WIdLI TIIck
1 Hurdbourd
or pIywood
1z" |oo| 1z" |oo| 1Jq" 6|
TIe mugneL IuyouLs ure dIIIerenL Ior LIe Lwo versIons
'EngIIsI' und 'MeLrIc'.
TIe druwIng on LIe nexL puge sIows LIe mugneL
posILIons druwn Lo scuIe. TIere Is onIy room Ior 1Jq
oI LIe mugneL roLor on LIe puge, buL you cun sLIII use
LIIs druwIng Lo muke LIe mugneL-posILIonIng jIg.
Use LIIs puge or u pIoLocopy oI IL Lo murk ouL LIe
mugneL posILIons on u pIece oI bourd us descrIbed
beIow. CIeck LIuL LIe dImensIons ure uccuruLe und
noL scuIed up or down by mIsLuke.
Murk LIe cenLre oI LIe bourd.
Druw Lwo cIrcIes wILI rudIus z"|o mm| und
q"|1oq mm| respecLIveIy.
Druw Lwo IInes LIrougI LIe cenLre oI LIe cIrcIes
uL rIgIL ungIes Lo eucI oLIer.
AIIgn LIe druwIng exucLIy on eucI quurLer oI LIe
jIg und murk LIe corners oI eucI mugneL wILI u
cenLre puncI or sIurp nuII.
Druw IInes connecLIng LIe puncI-murks, und cuL
uIong LIe IInes Lo creuLe LIe jIg. Use u jIg-suw
(US = subresuw) or u bundsuw.
CIeck wILI u mugneL Ior u Iree sIIdIng IIL.
You wIII uIso need 1Jz" |1z mm| IoIes on LIe z"|o mm|
rudIus cenLres Lo IocuLe LIe jIg durIng use. recommend
you jusL use Lwo boILs Lo do LIIs, so Lwo IoIes ure
suIIIcIenL. recommend usIng u smuII pIIoL drIII IIrsL Lo
esLubIIsI u reIIubIe cenLre, IoIIowed by u 1Jz" |1z mm|
drIII Lo IIL LIe 1Jz"|M1z| boIL. AIso drIII LIe Index IoIe Lo
IeIp keep Lruck oI LIe mugneL poIe posILIons.
TIe IInIsIed jIg Iooks IIke LIIs
MARK THE CORNERS
WITH A PUNCH
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 BZ
!'6:H?I"8+(6#(5*JI"J'K
4"
2"
1"
2"
30
46
104 mm
RADIUS OF ARC
TEMPLATE FOR
MAGNET POSITIONING
JIG
50 mm
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 BS
!'6:H?I"8+(6#(5*JI"J'K
@+K(56 %:7 %#" 8"%"8 ="')*?
*%#-3+%&)
PIeces MuLerIuI engLI WIdLI TIIck
q Ioor bourd 16" |qoo| 16" |qoo| Jq" |1q|
z PIywood 6" |18| 6" |18| 1Jz" |1o|
z Hurdbourd 16" |qoo| 16" |qoo| 1J8" | |
q BoILs,nuLs+
wusIers
"
|;o mm|
1Jz"
|1z mm|
q Screws
SIIIcone
seuIunL
Wux poIIsI
TIe mugneLs ure mounLed on J16" |8 mm| sLeeI pIuLes
LIuL Iuve been drIIIed Ior mounLIng on LIe wIeeI-Iub.
We embed LIe mugneLs In resIn Lo supporL LIem Irom
IIyIng oII und Lo proLecL LIem Irom moIsLure LIuL wouId
cuuse corrosIon. TIere Is one mouId Ior eucI roLor.
>*$%V I+"%
L Is u good Ideu Lo uIso drIII LIe Index IoIe Ior eucI
mugneL pIuLe In eucI mouId und In LIe jIg, LukIng cure Lo
ensure LIuL everyLIIng Is ussembIed LIe rIgIL wuy up.
TIIs wIII keep uII LIe mugneLs correcLIy uIIgned.
<#)(& +L (I% 2+-"$&
Muke LIe buse oI
eucI mouId Irom
LIIck bourd wILI u
smooLI IInIsI, (LIe
sume us LIe sLuLor
mouId buse). CuL
u squure 16" x 16"
|qoo x qoo mm|,
murk LIe cenLre,
und druw u cIrcIe 6
1Jq" |1 mm|
rudIus Lo IeIp you
posILIon LIe
surround on IL.
PIuce LIe sLeeI dIsk
uL LIe exucL cenLre oI LIe buse, und ;3+&& one or Lwo 1Jz"
|1z mm| IoIes, und LIe Index IoIe LIrougI IoIes In LIe
pIuLe. CounLerbore LIe IoIes Irom LIe underneuLI Lo
uccommoduLe LIe Ieuds oI LIe boILs.
TIese boILs wIII IuLer be used Ior posILIonIng LIe sLeeI
pIuLe, jIg und IsIund. Use LIe sLeeI pIuLe Lo guIde LIe drIII.
TIe ).33".!;) ure uIso 16" x 16" x Jq" |qoo x qoo x 1q
mm| bourds wILI u 1z 1Jz" |1o mm| dIumeLer IoIe cuL
In IL, Lo Iorm LIe edge oI LIe roLor cusLIng.
TIe +)&%!;) ure mude Irom 1Jz" |1o mm| pIywood.
TIey keep LIe resIn oII LIe cenLruI porLIon oI LIe sLeeI
dIsks wIere LIe mounLs wIII be. TIe IsIund dIumeLer Is
6" |18 mm|(sume us LIe sLuLor-mouId IsIund). AguIn,
eucI IsIund needs Lo Iuve IoIes uL LIe correcL posILIons
Lo cenLre IL on Lop oI LIe sLeeI dIsk.
InuIIy you wIII need &+;) Ior LIe mouIds. CuL LIese ouL
LIese Irom 16" x 16" x 1J8" |qoo x qoo x mm|
Iurdbourd or unyLIIng LIIn und sIIppery. C3+&&
oversIzed IoIes Lo IIL over LIe nuLs on LIe Lwo boILs LIuL
secure LIe IsIund.
]+&& %!; )%!;<%<-3 uny cuvILIes In LIe edges oI LIe
bourds wIere LIe resIn mIgIL peneLruLe und sLIck.
1,3-' LIe surround Lo LIe buse, und run some sIIIcone
uround LIe joIn. CouL LIe surIuces wILI wux poIIsI,
IncIudIng LIe IsIund (uII over) und LIe IId. Be IIberuI wILI
poIIsI on LIe InsIde oI LIe surround, und LIe ouLsIde oI
LIe IsIund. Cover uny screwIeuds wILI poIIsI Lo IucIIILuLe
dIsussembIy IuLer.
SURROUND
ISLAND
BASE
1/2" [12 mm] HOLES
12 1/2" [310] OD CIRCLE
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 BW
!'6:H?I"8+(6#(5*JI"J'K
L+?%(56 %:7 8"%"8?
<)%F#)#(.+*
*%#-3+%&)
PIeces MuLerIuI DIumeLer TIIck
z SLeeI pIuLe dIsks 1z " O.D.
|oo mm|
J16"
8 mm
QuunLILy MuLerIuI
z.Ibs
|1 kg|
PoIyesLer resIn (premIxed wILI ucceIeruLor)
cusLIng resIn or IIbregIuss resIn In IIquId
Iorm. PeroxIde cuLuIysL Lo suIL.
z. Ibs.
|1 kg|
TuIcum powder
' x 18"
|1 x . m|
IbregIuss cIoLI or cIopped sLrund muL
(1 ounce per sq. IooL) or |oog per sq. meLre|
zq MugneL bIocks z x 1 x 1Jz" grude NdeB
|q6 x o x 1o mm grude qo NdeB|
PIeces oI sLeeI, spunners eLc Lo Ioud LIe IIds.
^.# ".# Lwo dIsks oI IIbregIuss cIoLI. OveruII dIumeLer
Is 1z" |oo mm| und cuL u cenLruI IoIe ubouL 6 1Jz" |1;o
mm| dIumeLer.
^5-,X LIuL LIe roLor dIsks Iuve uII LIe necessury IoIes
drIIIed, und LIe IronL dIsk Ius Lupped IoIes reudy Ior LIe
juckIng screws.
JusL beIore cusLIng LIe roLors, )%!; uny mIII-scuIe oII
LIe ureu wIere LIe mugneLs wIII sIL, und ,&-%! LIem Lo
remove uny greuse.
\&%,- LIe dIsks onLo LIe Lwo posILIonIng boILs. TIe
sunded sIde sIouId be uppermosL und LIe Index IoIes
sIouId be uIIgned.
?#*$".*/ (I% 2#/*%(&
TIe NeodymIum ron Boron bIocks ure mugneLIsed
LIrougI LIeIr LIIckness so us Lo produce u norLI poIe on
one Iuce und u souLI poIe on LIe oLIer. NorLI und souLI
poIes uLLrucL eucI oLIer. NorLI repeIs norLI und souLI
repeIs souLI.
TIe mugneL bIocks ure very sLrongIy uLLrucLed Lo eucI
oLIer, und Lo sLeeI. HoId onLo LIem very LIgILIy wILI
boLI Iunds wIIIe IundIIng LIem, or LIey wIII IIy ouL oI
your grusp unexpecLedIy, und muy breuk or cuuse
InjurIes. MosL peopIe ure Luken by surprIse und muny
Iuve pIncIed IIngers us u resuIL.
MugneLs uIso pose u reuI LIreuL Lo mugneLIc medIu sucI
us credIL curds, sIm curds, IIoppy dIsks eLc. TIey cun
dumuge wuLcIes und cumerus. Keep LIe mugneLs und
LIe medIu upurL. Remove vuInerubIe ILems Irom pockeLs.
SLore mugneLs on u sIeII unLII you need LIem.
A)1 )-*
BeIore sLurLIng Lo mIx resIn Ior LIe roLor cusLIngs, Lry u
'dry run' oI ussembIy. PIuce LIe mugneL-posILIonIng jIg
onLo LIe Lwo M1z boILs. Tuke mugneL bIocks Irom LIe
sLock one by one, und pIuce LIem onLo LIe sLeeI pIuLe.
HoId eucI bIock wILI boLI Iunds und sIIde IL InLo pIuce
us Iur us possIbIe beIore reIeusIng IL.
=I%5M.*/ L+) 2#/*%( F+"#).(1
TIe mugneLs poIes uILernuLe norLI-souLI-norLI uround
LIe cIrcIe. TIereIore eucI bIock Ius Lo be LIe rIgIL wuy
up.
EucI LIme u mugneL bIock Is pIuced, 5"&; +# %0"M- +#)
!-+N50".3 jusL prevIousIy pIuced. L sIouId be
repeIIed. I IL Is uLLrucLed, LIen Lurn IL over und Lry uguIn.
I IL Is repeIIed LIen pIuce IL InLo ILs sIoL wILIouL LurnIng
IL over uguIn. TIIs wIII ensure LIuL IL Ius dIIIerenL
poIurILy Irom LIe prevIous bIock. CIeck uII LIe mugneLs
In posILIon perIodIcuIIy wILI u mugneL In your IIsL. Your
IIsL sIouId be uILernuLeIy uLLrucLed und repeIIed us you
progress uround LIe cIrcIe. HoId on LIgIL!
WIen IL comes Lo IILLIng mugneLs Lo LIe second dIsk you
musL ensure LIuL LIe mugneLs opposILe LIe Index murk
wIII be oI opposILe poIurILy. TIIs wIII ensure LIuL LIe
mugneL roLors wIII uLLrucL eucI oLIer.
WIen you ure suLIsIIed LIuL everyLIIng Is Lo Iund und
LIuL LIe mugneLs cun be suIeIy posILIoned, IL Is possIbIe
Lo sLurL mIxIng LIe resIn.
<-((.*/ .( (+/%(I%)
*+2 1Jz Ib. |zoo g| oI resIn wILI 1Jz LeuspoonIuI | cc|
oI cuLuIysL.
\%+!# LIIs mIxLure over LIe ureu oI sLeeI wIere LIe
mugneL bIocks wIII IIe, und uIIow some Lo run over LIe
edge oI LIe sLeeI dIsk (uIreudy In LIe mouId).
IL LIe mugneL-posILIonIng jIg, und +!)-3# #5- /%N!-#)
Lo eucI roLor cusLIng In Lurn, removIng LIe jIg once LIey
ure uII In posILIon.
PIuce LIe +)&%!;) onLo LIe boILs. CIump LIem down
onLo LIe dIsk wILI 1Jz" |M1z| nuLs und wusIers Lo
prevenL resIn Irom IeukIng under LIem.
EACH BLOCK HAS
A 'N' AND A 'S' POLE
N AND S POLES ATTRACT
EACH OTHER
POLES WHICH ARE THE SAME
REPEL EACH OTHER
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 DC
!'6:H?I"8+(6#(5*JI"J'K
I LIe IIquId mIx Is
sLIII usubIe, %;;
#%&,./ <"';-3
Lo IL und pour LIe
mIx InLo LIe spuces
beLween LIe
mugneLs.
*+2 unoLIer 1 Ib.
|qoog| resIn wILI 1
1Jz Lsp. |6 cc| oI
cuLuIysL und LIen
oo g oI LuIcum
powder und pour
LIIs mIx In nexL.
^"!#+!.- #" /+2
und pour resIn
unLII LIe IeveI rIses
Lo LIe Lop oI LIe
mugneLs. PuInL
resIn over LIe
mugneL Iuces.
Tuke cure Lo %M"+; #3%<<+!N %+3 In LIe spuce uround
LIe edge oI LIe sLeeI dIsks. Use vIbruLIon Lo dIsIodge
bubbIes und seLLIe LIe resIn mIx.
WIen LIe resIn IIIIs boLI LIe mouIds und Ius seLLIed ouL
mosL bubbIes, &%( #5- 4+03-N&%)) ,&"#5 ;+)Xs on Lop,
LukIng cure Lo cenLruIIse LIem. PuInL LIe cIoLI wILI resIn.
InuIIy Iuy on LIe Iurdbourd &+;). CIump LIe IIds down
by pIucIng sLeeI objecLs sucI us spunner, nuIIs eLc onLo
LIe surIuce oI LIe IId. TIe mugneLs wIII puII LIem down
und squeeze LIe resIn Iuyer Lo u mInImum.
MonILor LIe curIng process, und udjusL LIe LemperuLure
us requIred, jusL us wILI LIe sLuLor cusLIng.
To exLrucL LIe roLors, IIrsL prIse oII LIe IIds, remove LIe
M1z nuLs und boILs, und knock LIe roLors ouL oI LIe
mouIds. InuIIy knock LIe IsIund ouL Irom LIe cenLre,
LIrougI LIe z 1Jz" |6mm| IoIe In LIe sLeeI pIuLe.
Do noL use vIoIenL bIows Lo reIeuse LIe cusLIng In cuse
you breuk LIe resIn or u mugneL. Use persIsLenL LuppIng
uII uround LIe edges und be puLIenL.
-.%",&/ 0*0#$1 #)$'%*
CI1 L-)"W
TIe power In LIe wInd Is proporLIonuI Lo LIe cube oI LIe
wIndspeed, so II LIe wIndspeed doubIes, LIen IL Is eIgIL
LImes us powerIuI. We couId desIgn Ior LIe IIgIesL
wIndspeed wIIcI couId ever Iuppen und Iurness ILs
power, buL LIen Ior qq.q% oI LIe LIme our wInd LurbIne
wouId be under-used und probubIy noL very eIIIcIenL
becuuse IL wouId Iuve u Iuge, Ieuvy uILernuLor und
reIuLIveIy LIny bIudes.
I LIe wIndspeed Increuses beyond u cerLuIn poInL LIere
Is u dunger oI overIoud. TIe uILernuLor und dIodes muy
overIeuL, LIe bIudes muy overspeed or LIe sIde IoudIng
on LIe musL or 'Lower' muy be Loo IIgI. To prevenL LIese
LIIngs Irom IuppenIng, we IIL LIe LurbIne wILI u IurIIng
LuII.
?+G (I% L-)".*/ (#." G+)M&
TIe wInd LIrusL on LIe roLor bIudes Is IndIcuLIve oI LIe
umounL oI power beIng cupLured by LIe mucIIne. WIen
LIuL LIrusL reucIes u cerLuIn IeveI, und LIe wInd Is geLLIng
sLronger, we wunL Lo prevenL LIe power IncreusIng
IurLIer. deuIIy we wouId IIke Lo conLInue producIng IuII
power In IIgIer wInds, wIIIe uvoIdIng overIoud.
YAWING
MOMENT
LIFT
FORCE
ON TAIL
RESTORING MOMENT
ISLAND
MAGNET
BLOCKS
JIG
MOULD
FIBREGLASS
CLOTH DISK
LID
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 DX
!'6:H?I"8+(6#(5*JI"J'K
We buIId LIe wInd LurbIne oII-cenLre, so LIe wInd LIrusL
(cenLred on LIe uILernuLor) Is uIwuys LryIng Lo Lurn LIe
mucIIne uwuy Irom LIe wInd. I IL Lurns uwuy uL un
ungIe Lo LIe wInd, LIIs reduces LIe IronLuI ureu und IImILs
LIe power IL cun cupLure. TIe LrIck Is Lo muke IL Iuce LIe
wInd wIen IL needs Lo und Lo Lurn uwuy by LIe rIgIL
umounL uL LIe rIgIL LIme.
TIe uILernuLor Is oIIseL so LIuL LIe wInd LIrusL ucLs uL u
"|1z mm| rudIus Irom LIe cenLre oI LIe 'yuw beurIng'
on wIIcI LIe wIoIe mucIIne swIveIs Lo Iuce LIe wInd.
TIIs meuns LIuL LIe LIrusL creuLes u 'yuwIng momenL' or
Lorque ubouL LIe uxIs oI LIe yuw beurIng. TIe wInd
LIrusL Is uIwuys LryIng Lo Lurn LIe bIudes uwuy Irom LIe
wInd.
n normuI operuLIng wIndspeeds, LIe Iorce oI LIe wInd
on LIe LuII counLerucLs LIe yuwIng momenL. WIen LIe
mucIIne LrIes Lo yuw ouL oI LIe wInd, LIe LuII swIngs InLo
u posILIon wIere IL produces u IIIL Iorce. TIuL IIIL Iorce
creuLes u resLorIng momenL wIIcI buIunces LIe yuwIng
momenL und LIe mucIIne sILs LIere In equIIIbrIum. We
deIIberuLeIy seL LIe LuII uL u sIIgIL ungIe Lo LIe sIde
opposILe LIe uILernuLor oIIseL so LIuL LIe equIIIbrIum Is
ucIIeved wILI LIe bIudes squureIy IucIng LIe wInd und
cuLcIIng LIe muxImum power.
=+*()+"".*/ (I% (I)-&( L+)5%
As wIndspeed Increuses, LIe LIrusL Increuses, und so
does LIe yuwIng momenL. However, LIe IIIL on LIe LuII Is
uIso IncreusIng und so LIe equIIIbrIum oI Iorces keeps LIe
bIudes IucIng LIe wInd.
TIe cIever purL oI LIe IurIIng desIgn Is In LIe wuy LIe LuII
Is mounLed. WIen LIe IIIL Iorce reucIes u cerLuIn
mugnILude, IL moves LIe LuII InLo u new posILIon. n LIIs
posILIon LIe bIudes cun Lurn uwuy Irom LIe wInd. TIe
LIrusL Iorce Is LIereby reduced und u new equIIIbrIum Is
esLubIIsIed.
We couId use u sprIng und u IInge Lo consLrucL u LuII
mounL LIuL yIeIds In LIIs wuy. BuL experIence Ius sIown
LIuL sprIngs vIbruLe, corrode und breuk. nsLeud we use
un IncIIned IInge sysLem wIIcI Iorces LIe LuII Lo rIse us IL
swIngs Lo LIe sIde. TIe weIgIL oI LIe LuII ILseII brIngs IL
buck down InLo LIe normuI posILIon. We cun conLroI LIe
wIndspeed uL wIIcI IurIIng Lukes pIuce by mukIng LIe
LuII IeuvIer or IIgILer.
TAIL MOVEMENT
WIND
DIRECTION
ROTOR BLADES ARE NOW FACING OFF
AT AN ANGLE TO THE WIND
PLAN VIEW
OFFSET = 5" [125 mm] WIND THRUST
YAWING
MOMENT
BLADES
TAIL
YAW
BEARING
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 DB
!'6:H?I"8+(6#(5*JI"J'K
Y+&8(I+%(56 %:7 %+() :(567
*%#-3+%&)
\+-,-) *%#-3+%& _-!N#5 C+%/A U5+,X
1 SLeeI pIpe
1 " nomInuI
bore
8"
|zoo mm|
1 J16"
|.q|
overuII
1J8"
| mm|
wuII
1 SLeeI pIpe
1 1Jq"
nomInuI bore
q'
|1zoomm|
1 J8"
|qz.z|
overuII
1J8"
| mm|
wuII
1 SLeeI pIpe
1 1Jq"
nomInuI bore
6"
|1o mm|
1 J8"
|qz.z|
overuII
1J8"
| mm|
wuII
1 SLeeI dIsk 1 J8"
|qz.z|
mInImum
J16"
|8 mm|
\+-,-) *%#-3+%& _-!N#5 I+;#5 U5+,X
1 SLeeI pIuLe q"
|1oo|
z 1Jq"
|6 mm|
J8"
|1o mm|
1 SLeeI bur 1z" |oo| 1 1Jz"|o| J16' |8|
TIe LuII IInge Is mude In LIe
sume IusIIon us LIe yuw
beurIng. L consIsLs oI u 1 1Jq"
nomInuI pIpe sIIpped over u 1"
nomInuI pIpe.
TIese pIpe sIzes ure used In
boLI LIe 'EngIIsI' und LIe
'MeLrIc' versIons.
TIe smuIIer, Inner pIpe Is Lo be
weIded Lo u sIuped pIece oI
J8" |1o mm| pIuLe. TIe oLIer
sIde oI LIe pIuLe Is weIded Lo LIe
yuw beurIng. TIe resuILunL
ungIe oI LIe Inner pIpe Is zo
degrees Lo LIe verLIcuI.
You cun cuL LIIs pIuLe ouL Irom q" x J8" |1oo x 1o mm|
IIuL bur. TIe zo-degree ungIe Is ucIIeved by mukIng one
sIde oI LIe pIuLe z J16" |; mm| Iong und LIe oLIer Jq"
|zo mm| Iong.
WeId LIe pIuLe onLo LIe 1" pIpe IIrsL, und LIen weId IL
onLo LIe yuw beurIngs us descrIbed beIow.
TIe IInge musL be weIded onLo LIe yuw pIpe In u
dIugonuI posILIon, us seen Irom ubove. TIe ungIe
beLween LIe pIpe und LIe roLor pIune Is degrees In LIIs
pIun vIew.
IInd LIuL LIe eusIesL
wuy Lo ucIIeve LIIs -
degree ungIe Is Lo seL
LIe yuw ussembIy up
on LIe bencI wILI LIe
uILernuLor-mounLIng
bruckeL uL degrees
Lo LIe IorIzonLuI.
TIen sIL LIe LuII
IInge pIpe und pIuLe
verLIcuIIy on Lop oI LIe
yuw Lube und weId IL
LIere.
AppIy pIenLy oI weIds
uL boLI sIdes oI LIe
sLeeI pIuLe. TIe LuII
wIII puL some crILIcuI
Iouds on LIIs purL.
Good quuIILy weIdIng
Is essenLIuI Iere.
35 degrees
48" [1200 mm]
"INCH AND ONE QUARTER" NOMINAL BORE STEEL WATERPIPE
TAIL HINGE
OUTER PIPE
NOTCH IN
OUTER PIPE
TAIL BOOM
4"
[100]
6"
[150]
WELDED
FABRICATION
110 DEGREES
FIND POSITIONS OF
NOTCH CUT LINES BY
FITTING TO
COMPLETED MACHINE
20
DEGREES
1 1/4" [30 mm]
END OF TAIL BOOM
2 3/16"
[56 mm]
4"
[100]
3/4"
[20]
1 3/8"
[60.3]
TAIL HINGE SIDE VIEW
YAW PIPE
TAIL
HINGE
INNER
PIPE
3/8"
[10mm]
STEEL
20 DEGREES
8"
[200 mm]
55 DEGREES
WORK BENCH
35
DEGREES
VERTICAL
THE SET UP
FOR WELDING
PROP UP THE
ALTERNATOR
BRACKET AT 55
DEGREES TO THE
WORKBENCH LEVEL
10 1/4"
[260 mm]
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 DD
!'6:H?I"8+(6#(5*JI"J'K
4I% (#." .(&%"L
TIe ouLer purL oI LIe LuII IInge beurIng Is u 6" |1o mm|
Iong pIece oI 1 1Jq" pIpe, wILI u sLeeI dIsk weIded on Lop.
TIe LuII boom Is u q8" |1zoo mm| pIece oI 1 1Jq" sLeeI
pIpe, weIded Lo LIIs ouLer purL oI LIe LuII IInge beurIng.
TIe overuII dIumeLer oI LIese pIpes Is 1 J8" |qz mm|.
To prepure LIe LuII boom Ior weIdIng Lo LIe IInge
beurIng, seL IL up uL un ungIe oI zo degrees oII LIe verLIcuI
und muke u verLIcuI cuL InLo LIe end, sLurLIng jusL InsIde
LIe rIgIL Iund wuII (see dIugrum prevIous puge). TIe
depLI oI LIIs cuL Is 1 1Jq" |o mm|. Now pIuce IL
IorIzonLuIIy und cuL squure ucross LIe pIpe Lo remove u
pIece und Ieuve u 'bIrd's mouLI' on LIe end oI LIe pIpe.
TIIs sIouId now IIL LIe ouLer purL oI LIe beurIng uL un
ungIe oI 11o degrees. Use un ungIe grInder Lo muke IL IIL
beLLer und LIen weId IL very sLrongIy.
SeL LIe wInd LurbIne In u vIce, or u dummy LowerJsLund
wILI yuw beurIng verLIcuI. Drop LIe LuII onLo ILs beurIng.
L wIII noL go uII LIe wuy Iome, becuuse LIe sLeeI pIuLe
geLs In LIe wuy. You wIII need Lo cuL u noLcI In LIe LuII
IInge ouLer pIpe Lo uccommoduLe LIe sLeeI pIuLe. TIe
sIupe oI LIIs noLcI wIII uIso conLroI LIe runge oI
movemenL oI LIe LuII us IL swIngs up und uIIows LIe
mucIIne Lo IurI.
TIe LuII sIouId sIL IorIzonLuIIy In ILs IowesL posILIon uL
un ungIe oI ubouL 8o degrees Lo LIe roLor bIudes, und
LIereIore 1o degrees uwuy Irom poInLIng sLruIgIL buck.
AL LIe Lop oI ILs swIng moLIon IL comes cIose Lo beIng
puruIIeI Lo LIe bIudes buL noL beyond LIuL poInL.
Use u Iucksuw or un ungIe grInder Lo cuL LIe noLcI. Try
Lo muke LIe corners smooLI und prevenL sLress
concenLruLIons. TIe pIpe muy noL buLL neuLIy uguInsL LIe
sLeeI pIuLe; LIe weIds muy geL In LIe wuy.
You muy LIen Iuve Lo udd exLernuI pIeces Ior exLru
sLrengLI und u more posILIve sLop.
TIe LuII vune needs u crosspIece uL LIe end oI LIe boom
Lo boIL onLo. suggesL someLIIng IIke u pIece oI IIuL sLeeI
bur 1z" x 1 1Jz" x J16" |oo x o x 8 mm|. Recess LIe
IIuL bur InLo LIe pIpe Lo creuLe u IIuL surIuce on LIe
wIndwurd sIde oI LIe LuII wIere LIe vune wIII sIL.
WuIL unLII LIe LuII boom Is
on LIe wInd LurbIne und ILs
noLcI Ius been cuL beIore
you seL up Lo weId LIe T
pIece on LIe end. TIIs wuy
you cun seL LIe T pIece
verLIcuI. A verLIcuI LuII
vune Iooks beLLer (uILIougI
IL mukes no dIIIerence Lo
LIe wuy IL works).
REAR VIEWS OF THE TAIL IN TWO POSITIONS
FULLY FURLED
NORMAL
POSITION
PLAN VIEW
TAIL
SWING
ARC
10 DEGREES
BEFORE CUTTING THE NOTCH IN THE TAIL HINGE OUTER PIPE
SET THE TAIL UP AS SEEN IN THIS PLAN VIEW
AND MARK THE EXTENT OF ITS SWING
THIS IS ALSO A GOOD TIME TO FIT THE VERTICAL PIECE
OF 300 X 30 X 8 FLAT BAR WHICH SUPPORTS THE TAIL VANE
END OF
TAIL BOOM
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 DP
!'6:H?I"8+(6#(5*JI"J'K
L'%%(56 "'% %:7 %+() E+57
You cun muke LIe LuII vune uny sIupe you IIke provIded IL
Is Iurge enougI. suggesL you use ubouL ' x z' |qoo x
6oo mm| ureu.
Here Is one wuy Lo muke u LIdy IookIng LuII vune.
*%#-3+%&)
\+-,-) *%#-3+%& _-!N#5 I+;#5 U5+,X
1 exLerIor
pIywood
6"
|qoo mm|
zq"
|6oo|
J8"
|q mm|
BoILs, nuLs z 1Jz"
|6o mm|
J8"
|M1o|
SLurL by mukIng
Lwo murks uL 6"
|1o mm| In Irom
LIe ends oI one oI
LIe Ionger sIdes.
Ind u buckeL or
pIuLe wILI
dIumeLer uround
zo mm und use
LIIs Lo round oII
LIe corners oI LIe
oLIer Iong sIde us
sIown. Druw u
IIne Irom LIe
murks you Iuve
mude so IL jusL
LoucIes LIe cIrcIes
you Iuve druwn.
InuIIy use LIe
sume buckeL or
wIuLever Lo round
oII LIe new corners creuLed by LIIs new IIne.
Use u jIgsuw Lo cuL ouL LIe LuII. Sund oII LIe edges Lo
remove spIInLers.
MounL LIe LuII on LIe LuII boom wILI LIree J8" |M1o|
boILs. One boIL pusses rIgIL LIrougI LIe boom, und LIe
oLIers cun be neur LIe ends oI LIe sLeeI crosspIece you
weIded Lo LIe end oI LIe boom.
@"'5%(56 %:7 :7+%?(5K
*%#-3+%&)
\+-,-) *%#-3+%& _-!N#5 I+;#5 U5+,X
1 AIumInIum
ungIe
1z"
|oo mm|
z"
|o|
J16"
| mm|
z BoILs und
nuLs
1" |z| 1Jq" |6|
6 BoILs und
nuLs
1" |z| J16" ||
BrIdge
recLIIIers
A 6-8ooV sIngIe pIuse
1 ConnecLor
bIock
TIe Len wIres Irom LIe sLuLor wIII suppIy AC ouLpuL Irom
LIe uILernuLor. TIIs Ius Lo be converLed InLo DC Ior
cIurgIng LIe buLLery. TIe brIdge recLIIIers converL AC
InLo DC. TIey Iuve Lo be mounLed on u IeuLsInk Lo keep
LIem cooI wIen IundIIng IIgI currenLs. or exumpIe
pIece oI z" x z" x J16" |o x o x mm| uIumInIum
ungIe wouId muke u suILubIe IeuL sInk. TIe IengLI oI LIe
IeuLsInk Is q" |zzo mm|.
IL LIe IeuLsInk Lo
LIe uILernuLor
supporL bruckeL
uIongsIde buL noL
LoucIIng LIe yuw
pIpe.
BoIL IL on wILI 1Jq"
|6mm| boILs. TIe
recLIIIers ure boILed
Lo LIe IeuLsInk wILI
J16" |-mm| boILs.
A juncLIon bIock Ior
LIe DC wIrIng Is
uIso useIuI.
FIVE
SINGLE-PHASE
BRIDGE
RECTIFIERS
ALUMINIUM
ANGLE
PLASTIC WASHING-UP BOTTLES
OR SIMILAR
CABLE TIE
36"
[900]
10"
[250]
6"
[150]
12" x 1 1/2" x 3/8"
[300 x 30 x 8]
BOLTS
USE A BUCKET TO
DRAWCORNERS
6"
[150]
24" [600]
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 DQ
!'6:H?I"8+(6#(5*JI"J'K
U??7=&)(56 %:7 +)%785+%"8
*%#-3+%&)
\+-,-) *%#-3+%& _-!N#5 I+;#5
SLuInIess sLeeI uII-LIreud
rod
q "
|8o mm|
1Jz"
|M1z|
q SLuInIess sLeeI uII-LIreud
rod
8"
|18omm|
1Jz"
|M1z|
z AII-LIreud rod wILI nuL
weIded on
6 "
|1omm|
1Jz"
|M1z|
qo SLuInIess sLeeI nuLs 1Jz"
|M1z|
<)%F#)#(.+*
CIeck LIuL LIe LIreuds uL LIe ends oI LIe sLuds ure cIeur
oI burrs, so LIuL LIe nuLs cun be udded uL eILIer end.
n LIe cuse oI LIe UK CuvuIIer Iub, LIe Iour nuLs uL LIe
buck oI LIe wIeeI Iub IIunge muy need Lo be ground Lo IIL
LIe curve oI LIe cusLIng on LIe InsIde. A beveI on one
corner Is usuuIIy suIIIcIenL. TIese nuLs musL seuL onLo
LIe buck oI LIe IIunge wILIouL puLLIng eccenLrIc Iouds on
LIe sLuds wIIcI wouId pusI LIem squInL und muke LIe
mugneL dIsks Iurd Lo IIL.
CIeun up LIe muLIng surIuces oI LIe mugneL dIsks so LIey
sIL Lrue on LIe Iub IIunge und mounLIng nuLs.
?-H #*$ &I#L(
BoIL LIe sIuIL IIunge Lo ILs bruckeL wILI Iour screws,
ensurIng LIuL IL sILs secureIy. ock LIe screws wILI
LIreudIock compound.
E%)%7' 57:<%0<6 &7$(.
DrIII LIree J16" | mm| IoIes In LIe sLuLor
dummy (LIe oII-cuL pIece oI pIywood Irom
mukIng LIe sLuLor mouId). Murk LIe sIde oI LIe
dummy LIuL represenLs LIe buck oI LIe sLuLor
(wIrIng exIL). PIuce LIIs sIde oI LIe dummy onLo
LIe IronL oI LIe sLuLor so LIuL IL Is ,-!#3-;, und
drIII pIIoL IoIes Ior LIe mounLIng sLuds, workIng
LIrougI LIe IoIes In LIe dummy InLo LIe sLuLor
cusLIng. EnIurge LIe IoIes Lo 1Jz" |1z mm|.
PIuce LIe buck oI LIe dummy (uguIn) on LIe
sLuLor mounLs so LIuL IL Is ,-!#3-; on LIe sIuIL
und LIe rIgIL wuy up so LIe sLuLor wIrIng wIII
emerge uL LIe buck oI LIe sLuLor. DrIII pIIoL
IoIes Ior LIe mounLIng sLuds, workIng LIrougI
LIe IoIes In LIe dummy InLo LIe sLuLor mounLIng
Iugs. EnIurge LIe IoIes Lo 1Jz" |1z mm|.
MounL LIe beurIng Iub und udjusL LIe beurIngs. IL LIe
dusL cover Lo LIe beurIng.
SeL LIe uILernuLor bruckeL IeveI on LIe bencI so LIuL LIe
Iub IIunge Is IeveI on Lop.
!#5M 2#/*%( )+(+)
SpIn Iour nuLs onLo eucI oI LIe Iour Iong sLuds und
LIgILen LIem evenIy uguInsL eucI oLIer so LIuL LIere Is
ubouL Jq" |zomm| oI Iree LIreud projecLIng.
Puss LIe sIorL end LIrougI LIe buck roLor und LIe Iub
IIunge. TIreud LIe (beveIIed) nuLs uL LIe buck oI LIe
IIunge (usIng LIreud-Iock), und LIgILen down so LIuL LIe
buck pIuLe Is Iocked In pIuce. Tuke cure noL Lo roLuLe LIe
beveIIed nuLs uL LIe buck or LIey wIII noL sIL Lrue.
RoLuLe LIe pIuLe on LIe beurIng und see LIuL IL runs Lrue.
A pIece oI copper wIndIng wIre uLLucIed Lo u sLuLor sLud
Is u good IndIcuLor oI Iow Lrue LIe dIsk Is. SeL LIe wIre
up so LIuL IL jusL brusIes uguInsL LIe mugneL surIuces. I
LIe dIsk does noL run Lrue LIen you muy Iuve Lo cIeun IL
beLLer wIere IL meeLs LIe IIunge.
4I% &(#(+)
SpIn Lwo 1Jz" |M1z| nuLs onLo eucI sLuLor-mounLIng
sLud, und puss LIe sLud ends LIrougI LIe sLuLor Iugs.
Add nuLs Lo LIe buck (wILI LIreud-Iock). SquIrL
LIreudIock beLween LIe Iug und LIe IIrsL nuL ubove und
LIgILen LIe nuL down.
CIeck LIuL LIe sLuLor IILs eusIIy onLo LIe LIree sLuds
beIore LIe sLud-Iock seLs (1o mInuLes). I noL LIen Lry Lo
udjusL LIe posILIons oI LIe sLuds, or enIurge LIe IoIes In
LIe sLuLor. VerIIy LIuL LIe sLuLor Is cenLruI reIuLIve Lo LIe
Iour roLor-mounLIng sLuds.
IL LIe sLuLor beLween nuLs und bIg wusIers. SpIn LIe
nuLs downwurd on LIe sLuLor sLuds so LIuL LIe sLuLor sILs
on LIe IIrsL mugneL roLor.
FOUR MOUNTING STUDS FOR
MAGNET ROTORS AND BLADES
3"x 1/2" [80mm]
STAINLESS STEEL
7 x 1/2"
[180 X M12]
BEARINGHUB
THREE MOUNTING STUDS
FOR STATOR
BEVEL
THESE
NUTS
TWO JACKING
SCREWS
6 x 1/2"
[150 X M12]
ALTERNATOR ASSEMBLY STUDS IN STAINLESS STEEL 1/2" [M12]
3/4 [20mm]
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 DR
!'6:H?I"8+(6#(5*JI"J'K
,)+*( 2#/*%( )+(+)
Now IIL LIe second mugneL roLor. TIe juckIng screws
sIouId be In pIuce und screwed down ubouL IuII wuy Lo
prevenL LIe roLor Irom crusIIng InLo pIuce. WIen LIe
screws muke conLucL wILI LIe IIrsL roLor, sLurL Lo unscrew
LIem, und uIIow LIe roLor Lo descend InLo pIuce genLIy
unLII IL resLs on LIe Iour nuLs.
AL LIIs poInL you cun cIeck LIe cIeurunce. Juck LIe sLuLor
upwurds genLIy, usIng nuLs on eucI oI ILs LIree mounLs,
unLII IL sLops rubbIng uguInsL LIe buck roLor. TIere
sIouId sLIII be ubouL 1J8" | mm| oI cIeurunce beLween
LIe sLuLor und LIe IronL roLor. RuIse LIe sLuLor unLII LIe
cIeurunce Is equuI on boLI sIdes.
I In doubL ubouL LIe cIeurunce, remove LIe IronL roLor
usIng LIe juckIng screws. AIIow LIe sLuLor Lo sIL buck
down on LIe buck roLor durIng LIIs operuLIon, so LIuL you
cun Iever uguInsL IL II necessury wILIouL undue sLress on
LIe sLuLor ILseII. PIuce wusIer(s) on eucI sLud Lo puck IL
IurLIer ouL. ReussembIe und Lry uguIn.
MugneLIc IIux Is beLLer II LIe mugneLs ure cIoser LogeLIer,
buL IL Is ImporLunL Lo keep LIem Iur enougI upurL Lo
uIIow Ior mIsIups und Ior weur In LIe beurIng.
ReIIubIIILy Is more ImporLunL LIun perIormunce.
WIen LIe cIeurunce Is correcLIy udjusLed, LIgILen uII LIe
nuLs usIng LIreud-Iock, und LesL LIe uILernuLor.
07?%(56 %:7 +)%785+%"8
;I+)( 5.)5-.( (%&(&
Muke sure LIuL none oI LIe wIres Irom LIe sLuLor Iuve
bure ends LoucIIng eucI oLIer. TIe sLuLor sIouId spIn
IreeIy.
SLrIp Lwo wIres Irom LIe sume IuII oI LIe sLuLor, und
LoucI LIem LogeLIer. TIe uILernuLor wIII become sLIII Lo
Lurn. TIe Lorque us you Lry Lo Lurn IL wIII puIsuLe. TIe
mugneLs puss cerLuIn posILIons wIere LIey produce Iurge
currenLs In LIe sIorL cIrcuIL.
ConnecL uII IIve wIres LogeLIer und LIe Lorque wIII be
smooLI und very sLIII. TIere wIII be currenL IIowIng uII
LIe LIme.
'= K+"(#/% (%&(&
DIsconnecL uny sIorL cIrcuILs und roLuLe LIe mugneLs
sLeudIIy. Use u muILImeLer on AC-voILuge runge Lo cIeck
LIe voILuge beLween uny puIr oI wIres Irom LIe sume IuII
oI LIe sLuLor. NoLe LIuL LIe voILuge vurIes In proporLIon
Lo LIe speed oI crunkIng. You wIII reud one oI Lwo
possIbIe AC voILuges, dependIng on LIe pIuse dIIIerence
beLween LIe wIres In u puIr. Ind u puIr wILI LIe IIgIer
voILuge beLween LIem.
TIe AC voILuge IndIcuLes LIe ouLpuL voILuge uL uny gIven
speed, buL LIe DC ouLpuL wIII be IIgIer by u IucLor oI
ubouL qo% LIun LIe AC voILuge, Iess u IIxed umounL
uround 1. voILs DC, due Lo LIe IIxed voILuge drop In LIe
recLIIIer. TIe reuson Ior LIe qo% dIIIerence Is LIuL LIe AC
reudIng Is un uveruge (rooL meun squure ucLuuIIy) vuIue,
wIereus LIe recLIIIed DC wIII be LIe peuk voILuge
uvuIIubIe.
Turn LIe mugneL roLors uL 6o rpm (once per second) und
meusure LIe AC voILuge. or u 1z voIL uILernuLor IL
sIouId be ubouL . voILs. To cIurge u 1z-voIL buLLery
you wIII need ubouL 16 rpm, uL wIIcI poInL LIe AC
voILuge wouId be q.6 voILs und LIe DC wouId LIereIore
be:
(1.q x q.6)-1. = 1z voILs DC.
A= K+"(#/% (%&(&
ConnecL LIe recLIIIer (see nexL puge) und cIeck LIe DC
ouLpuL wIIIe crunkIng LIe uILernuLor. L wIII be dIIIIcuIL
Lo monILor LIe rpm by counLIng, buL you cun use u
muILImeLer wILI Irequency LesLIng ubIIILIes. ConnecL LIe
Irequency meLer Lo uny puIr oI AC wIres und LIe Hz
reudIng wIII be 1J1o oI LIe rpm. As u ruIe:
requency In Hz = rpm x number oI poIes J 1zo
I you cun crunk IL IusL enougI IL sIouId be possIbIe Lo
obLuIn 1z voILs DC uL ubouL 16 rpm (16. Hz).
NoLe LIuL wIen LIe DC wIres ure sIorLed LogeLIer LIe
uILernuLor Is sLIII eusy Lo Lurn uL Iow speeds buL becomes
LOWERING THE SECOND ROTOR
INTO PLACE
STATOR
FRONT ROTOR
BACK ROTOR
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 DZ
!'6:H?I"8+(6#(5*JI"J'K
very Iurd Lo Lurn IusLer LIun ubouL LImes per second.
TIIs Is becuuse LIe dIodes In LIe recLIIIer do noL conducL
unLII LIere Is u voILuge uround 1. voILs ucross LIem In
LoLuI. TIen LIey wIII conducL, und LIe Lorque wIII rIse
rupIdIy.
L"557I%(56 %:7 87I%(<(78
TIe ucLuuI wIrIng beLween coIIs und
recLIIIer Is sImpIe. EucI oI LIe Len wIres Is
LermInuLed on un AC LermInuI oI LIe
recLIIIer. AC LermInuIs ure In dIugonuIIy
opposILe corners.
TIe DC LermInuIs ure recognIsubIe becuuse
LIe posILIve LermInuI Is uL rIgIL ungIes Lo
LIe oLIers.
TIere ure Lwo wuys Lo connecL Lo LIe
brIdge recLIIIers. TIe eusIesL wuy Is Lo use
crImped 'IusLon' or 'recepLucIe' pusI-IIL
connecLors, wIIcI sIIp onLo LIe bIude
LermInuIs on LIe recLIIIer unILs. Tuke cure
LIuL LIe bIude enLers LIe rIgIL sIoL, und
does noL Iorce ILseII beLween LIe recepLucIe
und ILs InsuIuLIng sIeeve.
A more secure meLIod oI connecLIon Is Lo
soIder wIres Lo LIe bIude LermInuIs. TIIs Is
onIy un ImprovemenL over LIe crImp
connecLors II LIe soIderIng LecInIque Is
very good.
n boLI cuses, LIe connecLIons wIII need Lo
be proLecLed uguInsL dump or LIey wIII
corrode und IuII. A pIusLIc boLLIe mukes u
good ruIn sIIeId.
L"557I%(56 %:7 &+%%78A
,-&%& +) 5.)5-.( H)%#M%)&
AIwuys use proLecLIon on every cIrcuIL
Irom u buLLery. TIIs Is un ImporLunL suIeLy
Issue. Use sepuruLe Iuses or breukers Ior
LIe wInd LurbIne und Ior LIe Iouds. Use smuIIer Iuse Ior
cIrcuILs wILI LIIn wIre sucI us LIe voILmeLer suppIy.
=+**%5(.+*&
Never use crocodIIe cIIps Ior u permunenL connecLIon Lo
u buLLery. CrImped Iugs ure LIe besL LermInuIs.
!)#M% &G.(5I
TIe bruke swILcI Is u useIuI IeuLure Ior sLoppIng LIe wInd
LurbIne II necessury. WIen you sIorL-cIrcuIL LIe
uILernuLor IL cun onIy Lurn very sIowIy. Do noL sIorL-
cIrcuIL LIe buLLery or you wIII bIow LIe Iuse.
I you dIsconnecL LIe wInd LurbIne Irom LIe buLLery, LIe
voILuge wIII be ouL oI conLroI und muy become
dungerousIy IIgI. Do noL LoucI uny bure wIrIng under
LIese condILIons. Do noL dIsconnecL LIe wInd LurbIne
Irom LIe buLLery or IL wIII run IusL und weur ILseII ouL.
An urrungemenL usIng u bIockIng dIode und cIungeover
swILcI soIves LIese Issues. TIe swILcI bypusses LIe
dIode In normuI use, Lo prevenL Ioss oI power In LIe
dIode. See dIugrum.
L:""?(56 ?'(%+&)7 #(87 ?(\7?
Power Is IosL In wIrIng due Lo ILs resIsLunce Lo currenL
IIow. TIe currenL IIow Is Iurger Ior Iower buLLery
voILuges. oss vurIes In proporLIon Lo LIe squure oI LIe
THE POSITIVE DC
TERMINAL IS AT 90
DEGREES TO THE
OTHER TERMINALS
EACH
COIL
FINISH
CONNECT
S TO AN
'AC'
TERMINAL
THERE ARE FIVE BRIDGE RECTIFIER
UNITS IN THE WIND TURBINE
THE RECTIFIERS CONVERT THE
ALTERNATING CURRENT (AC) INTO
DIRECT CURRENT (DC) FOR THE
BATTERY
-
+
V
STOP
GO
'BLOCKING
DIODE'
CABLE TO BATTERY
LOCATION
- +
12 VOLT BATTERY
FUSES OR CIRCUIT
BREAKERS CABLE TO
LOADS
FUSE
CONTROL
BOX
A
DONOT USE 'CROCODILE CL
FORPERMANENTCONNECTIO
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 DS
!'6:H?I"8+(6#(5*JI"J'K
currenL, so 1z-voIL buLLery sysLems wIII end mucI LIIcker
wIre LIun q8 voIL buLLery sysLems.
TIe wIres Irom LIe wInd LurbIne Lo LIe buLLery Iuve Lo be
Iurge enougI Lo curry LIe currenL wILIouL over-IeuLIng.
BuLLery MInImum wIre sIze Ior
oo wuLLs
1z-voILs #1o |6 mm|
zq-voILs #1z |z. mm|
q8-voILs #1q |1. mm|
I LIe wIre run Is Iong LIen you uIso need Lo cIeck
wIeLIer LIe power IosL Is uccepLubIe. Use LIIcker wIres
Ior Ionger runs. TIe wIre run Is LIe dIsLunce Irom LIe
wInd LurbIne Lo LIe buLLery one wuy. TIe cuIcuIuLIons
ussume u Iow wIre LemperuLure uround normuI umbIenL.
TIe wIre run Is LIe dIsLunce Irom LIe wInd LurbIne Lo LIe
buLLery one wuy. TIe cuIcuIuLIons ussume u Iow wIre
LemperuLure uround normuI umbIenL.
TIe LubIe ussumes LIuL oo wuLLs Is reucIIng LIe buLLery
und LIuL IL Is uL nomInuI voILuge. TIe % IIgure Is LIe Ioss
us u % oI LIe LoLuI power generuLed. I LIe percenLuge
Ioss Is IIgI LIen LIe wInd LurbIne wIII Iuve Lo produce u
IoL oI exLru power. TIIs cun onIy Iuppen wIen LIere Is
enougI wInd. So you wIII geL Iess power uL LIe buLLery In
uny gIven wIndspeed. TIe mucIIne muy Lurn uwuy Irom
LIe wInd (IurI) beIore you geL oo wuLLs Lo LIe buLLery
under LIese condILIons. L muy be necessury Lo udd
weIgIL Lo LIe LuII Lo geL IuII ouLpuL. Do noL worry ubouL
overIoudIng LIe uILernuLor. So Iong us LIe currenL Is noL
Increused LIen IL wIII noL overIeuL.
Some oI LIe Ioss IIgures Iook uwIuI buL LIey ure noL us
bud us LIey seem. Beur In mInd LIuL mosL oI LIe LIme LIe
wInd mucIIne wIII be generuLIng Iess LIun ILs IuII ouLpuL.
TIe mosL ImporLunL condILIons Lo Iuve good eIIIcIency
ure Iow wIndspeed condILIons. AL IuII power LIe Ioss
percenLuge Is onIy one IuII oI LIe % sIown.
AnoLIer mILIguLIng IucLor Is LIe ImprovemenL oI bIude
eIIIcIency wIen LIey run IusLer. TIIs uILernuLor IoIds LIe
bIudes speed down very Iow uL IIgI power, wIIcI Is nIce
Irom LIe poInL oI vIew oI mInImIsIng nose, buL cun cuuse
LIe bIudes Lo sLuII. I LIe wIre Ioss Is IIgI LIen LIe
uILernuLor Ius Lo run IusLer Lo produce LIe IIgIer
voILuge. TIIs wIII probubIy meun LIuL LIe bIudes work
beLLer.
C.)% (1F%
Use IIexIbIe LougI, sIngIe conducLor wIres In LIe Lower
drop wIere LIe cubIes wIII be subjecL Lo movemenL und
LwIsLIng.
Use IeuvIer cubIe Ior IIxed wIre runs und proLecL IL wILI
conduIL or use urmoured cubIe.
Percentage power lost in wiring from wind
turbine to battery for 500 watt output t o
battery
Wire run Battery
Voltage
Wire
Size 100'
[ 30m]
200'
[60 m]
300'
[90 m]
12 V #10 41% 59% 68%
12 V # 8 31% 47% 57%
12 V # 6 22% 36% 46%
12 V # 4 15% 26% 35%
12 V # 2 10% 18% 25%
24 V #12 22% 36% 46%
24 V #10 15% 26% 35%
24 V # 8 10% 18% 25%
24 V # 6 7% 12% 17%
24 V # 4 4% 8% 12%
24 V # 2 3% 5% 8%
48 V #12 7% 12% 17%
48 V #10 4% 8% 12%
48 V # 8 3% 5% 8%
48 V # 6 2% 3% 5%
48 V # 4 1% 2% 3%
48 V # 2 1% 1% 2%
Wire run Battery
Voltage
Wire
area
Sq.mm
100'
[ 30m]
200'
[60 m]
300'
[90 m]
12 V 2.5mm 60% 75% 82%
12 V 6.0mm 38% 55% 65%
12 V 10.0mm 27% 43% 53%
12 V 16.0mm 19% 32% 41%
12 V 25.0mm 13% 23% 31%
12 V 35.0mm 10% 18% 24%
24 V 2.5mm 27% 43% 53%
24 V 6.0mm 13% 24% 32%
24 V 10.0mm 9% 16% 22%
24 V 16.0mm 5% 10% 15%
24 V 25.0mm 4% 7% 10%
24 V 35.0mm 3% 5% 7%
48 V 2.5mm 9% 16% 22%
48 V 6.0mm 4% 7% 10%
48 V 10.0mm 2% 4% 7%
48 V 16.0mm 1% 3% 4%
48 V 25.0mm 1% 2% 3%
48 V 35.0mm 1% 1% 2%
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 DW
!'6:H?I"8+(6#(5*JI"J'K
Y(%%(56 +5* &+)+5I(56 %:7 &)+*7?
WIen LIe uILernuLor Ius been ussembIed und LIe
mucIIne Is eIecLrIcuIIy reudy Ior erecLIon, IL Is LIme Lo IIL
LIe roLor bIudes. SeL LIe mucIIne up on u sLund so LIuL IL
Is ubouL 1. meLres ubove IIoor IeveI, und secureIy
supporLed. BuIuncIng cun onIy be done In u sIeILered
pIuce, so IL Is wIse Lo IIL LIe bIudes In LIe worksIop
ruLIer LIun In LIe IIeId.
TIe roLor bIude ussembIy Is usuuIIy quILe u LIgIL IIL onLo
LIe Iour M1z sLuds und muy need Lo be drIven on wILI
muIIeL bIows. AvoId exLreme sIocks Lo LIe uILernuLor In
cuse you dumuge one oI LIe mugneL roLor cusLIngs. AS
soon us LIe LIps oI LIe sLuds uppeur LIrougI LIe IronL oI
LIe roLor, IIL wusIers und nuLs Lo LIem und use LIe nuLs
Lo IInIsI pusIIng LIe roLor Iome.
=I%5M.*/ (I% ()#5M.*/
WIen LIe bIudes ure on, IIrsL cIeck LIe LruckIng oI LIe
LIps. PIuce u cIuIr or sImIIur objecL ver cIose Lo one LIp
und roLuLe LIe oLIers pusL LIe sume objecL. TIey sIouId
IoIIow eucI oLIer LIrougI spuce wILIIn ubouL 1o mm. I
one bIude Is Iorwurd compured Lo LIe oLIers, you cun
usuuIIy correcL LIIs by LIgILenIng LIe nuLs Iurd on LIuL
sIde oI LIe roLor. TIIs crusIes LIe pIywood sIIgILIy und
correcLs LIe LruckIng. L Is uIso possIbIe Lo use sIIm
wusIer buL In prucLIce IL Is very Iurd Lo IInd LIIn enougI
ones und geL LIem rIgIL. Rubber wusIers (Irom Inner
Lubes) cun be used InsLeud oI crusIIng LIe pIywood II you
preIer.
!#"#*5.*/ (I% )+(+)
TIe gouI oI LIIs procedure Is Lo sLuLIc-buIunce LIe roLor
ussembIy. DynumIc buIuncIng Is noL necessury Ior our
purposes. ProvIded LIe LIps Lruck eucI oLIer LIen LIe
dynumIc buIunce wIII be IIne once IL Ius been sLuLIc-
buIunced.
WIen IIrsL ussembIed, LIere Is normuIIy u conspIcuous
ImbuIunce In LIe roLor. L wIII swIng uround InLo u
preIerred posILIon. TIIs Is LIe posILIon wIere LIe cenLre
oI gruvILy oI LIe roLor Is beIow LIe cenLre oI LIe sIuIL
(IIke u penduIum). Try deIIecLIng IL cIockwIse und
unLIcIockwIse und wuLcI IL reLurn Lowurd ILs preIerred
posILIon. L muy noL geL LIere, becuuse oI IrIcLIon In LIe
beurIngs. HeIp IL by LuppIng LIe uILernuLor mounLs.
CureIuIIy observe LIe posILIon IL IIkes Lo come Lo resL.
Tuke un uveruge.
Muke u counLerweIgIL Irom u pIece oI Ieud IIusIIng und
IIx IL LemporurIIy onLo LIe roLor uL u poInL dIrecLIy ubove
LIe cenLre wIen IL Is In ILs preIerred posILIon. TIe
neuLesL pIuce Lo IIL LIIs weIgIL Is usuuIIy In beLween LIe
Lwo pIywood dIsks. AddIng weIgIL Iere wIII move LIe
cenLre oI gruvILy upwurd Lowurd LIe cenLre oI roLuLIon
und sIouId IeIp Lo buIunce LIe roLor. However IL Is Iurd
Lo know exucLIy Iow mucI weIgIL Lo udd.
To cuIIbruLe LIe weIgIL, you Iuve Lo cIeck uguIn Ior
buIunce. RoLuLe LIe roLor qo degrees cIockwIse und
observe wIeLIer IL Ius uny Lendency Lo move rIgIL or
IeIL. AdjusL LIe sIze oI LIe weIgIL unLII LIere Is no
Lendency Lo swIng In eILIer dIrecLIon. You cun uIso LrIm
LIe buIunce by movIng LIe weIgIL IorIzonLuIIy cIoser Lo
or IurLIer Irom LIe cenLre. MovIng IL Lo LIe rIgIL wIII
counLerucL u Lendency Lo swIng unLIcIockwIse Ior
exumpIe.
,.*% (-*.*/
Try LIe roLor In u number oI posILIons, und vIbruLe LIe
mounLIng In un uLLempL Lo muke IL move. AL LIIs sLuge
you ure IookIng Ior u very smuII ImbuIunce. I you cun
IInd uny Lendency Lo move wIen IL Is In u purLIcuIur
posILIon, LIen Lry LurnIng IL 18o degrees und see II IL
Lends Lo move LIe oLIer wuy. Add u very smuII weIgIL Lo
LIe sIde wIere IL wunLs Lo rIse. AdjusL LIe sIze und
posILIon oI LIIs weIgIL unLII LIere Is no percepLIbIe Lrend
Lo roLuLe In eILIer dIrecLIon.
TIe ubove procedure wIII resuIL In u smooLI runnIng
roLor unIess LIe beurIngs ure excepLIonuIIy sLIII. I you
wIsI Lo IIne-Lune IL sLIII IurLIer, you cun Lry LIe
IoIIowIng. Hung u smuII weIgIL (ubouL o grums) on one
oI LIe sLuds. CIoose jusL enougI weIgIL Lo sLurL IL
LurnIng. Hung LIe sume weIgIL on LIe opposILe sIde und
cIeck LIuL IL sLurLs In LIe opposILe dIrecLIon. I noL LIen
you muy Iuve Lo IIx u IILLIe buIunce weIgIL on LIuL sIde.
Do LIe sume LesL wILI LIe roLor In severuI posILIons.
WIen you ure Iuppy LIuL you Iuve cIosen suILubIe
weIgILs und posILIoned LIem correcLIy Lo buIunce LIe
roLor, LIen screw LIe weIgILs secureIy Lo LIe bIudes so
LIey cunnoL IIy oII wIen LIe roLor Is spInnIng IusL.
IF THE ROTOR SWINGS INTO THIS POSITION
THEN ADD WEIGHT HERE. THIS MOVES THE
CENTRE OF GRAVITY UPWARDS
NEXT ROTATE IT 90 DEGREES,
AND CHECK THAT THE AMOUNT
OF WEIGHT ADDED IS CORRECT
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 PC
!'6:H?I"8+(6#(5*JI"J'K
U//-0-M.UT -.YM2@U0-M.
O'A7* %"#78 (*7+?
TIe musL or 'Lower' Is usuuIIy mude Irom sLeeI wuLerpIpe.
z" pIpe Is suIIIcIenL, buL Iurger sIzes ure uIso OK. TIe
Lower musL be LuII enougI Lo Luke LIe wInd LurbIne up
und ouL oI uny LurbuIence, InLo u good cIeun wInd. TIe
IIgIer LIe beLLer Is u good ruIe, buL opLImum IeIgIL wIII
depend on IocuLIon. n u very open IocuLIon u zo' |6
meLre| Lower mIgIL do. n muny cuses IL wIII be
necessury Lo go Lo qo' |1z m| or 6o' |18 m| Lo reucI cIeun
wInd. n LIe USA, 1zo' |6 m| ure noL uncommon.
MukIng sucI u LuII Lower In IIgILweIgIL pIpe requIres
muny guy cubIes.
TIe Lower Lop needs Lo consIsL oI u qoo mm Iong pIece oI
1." pIpe (q8 mm overuII). TIIs wIII sIIp InsIde LIe yuw
pIpe. You cun buLL weId LIe 1." pIpe dIrecLIy Lo u z"
pIpe, II your weIdIng Is good. I In doubL, LIen use pIeces
oI IIuL bur uIongsIde LIe joIn und overIuppIng Lo sLIIIen IL.
I LIe pIpe sIze Is Iurger LIen use un udupLer pIuLe wILI u
Iurge IoIe In IL Ior LIe wIrIng. A o-mm IoIe wouId be
IdeuI, so LIuL LIe smuIIer pIpe cun puss LIrougI IL und be
weIded on boLI sIdes.
TIere ure muny wuys Lo uLLucI guys Lo LIe Lower. One
good soIuLIon Is LIe sIIce sIorL pIeces oI sLeeI pIpe In IuII
IengLIwuys, und weId LIem onLo LIe sIde oI LIe Lower us
sIown. TIen LIe LIe guys uround LIe Lower, pussIng
LIrougI LIe IuII-pIpes. Muke sure LIe guys ure weII cIeur
oI LIe bIude LIps, buL noL so Iur beIow LIem LIuL LIe
bendIng Ioud on LIe Lower Is excessIve In sLrong wInds.
IL guys Lo LIe Lower uL upproxImuLeIy q meLre InLervuIs
uIong ILs IengLI. TIe Lop guys need Lo be sLrong; LIe
oLIers sImpIy provIde sLIIIness.
Guys ure LrudILIonuIIy mude Irom sLeeI wIre rope. Even
guIvunIsed wIre rope Ius u IImILed IIIe spun, suy IIve Lo
Len yeurs. OLIer opLIons IncIude IIbre rope Ior u
Lemporury InsLuIIuLIon, Ience wIre Ior Iow cosL und
durubIIILy (buL bewure - wIres cun snup!), or guIvunIsed
cIuIn Ior reuI peuce oI mInd on sIorL Lowers.
TIe buse oI LIe Lower cun be IInged In u number oI
dIIIerenL wuys. SLeeI ungIe cun be used Ior LIIs. Muke
sure LIuL LIere Is cIeurunce Ior LIe wIrIng Lo emerge
smooLIIy Irom LIe boLLom In sucI u wuy LIuL IL Is eusy Lo
cIeck Ior LwIsLIng.
TAIL HINGE
WIND TURBINE
TOWER 2" = 60mm
STEEL PIPE
ADAPTER
PLATE
WIND TURBINE
TOWER 3" = 89mm
STEEL PIPE
4
0
0

m
m

1
.
5
"

=

4
8

m
m

P
I
P
E
1
1
0
0

m
m
YAW PIPE 2" = 60 mm
BUTT
WELD
HINGE PIN
TOWER PIPE
WELDED STEEL
ANGLES
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 PX
!'6:H?I"8+(6#(5*JI"J'K
L"5%8"))(56 %:7 &+%%78A I:+867
8+%7
eud ucId buLLerIes sIouId be kepL In u cIurged
condILIon. n LIe cuse oI u wInd-powered sysLem, you
muy Iuve Lo wuIL Ior u wInd Lo cIurge LIe buLLery. BuL be
cureIuI noL Lo dIscIurge LIe buLLery Loo deepIy, or Lo keep
IL Loo Iong In u dIscIurged sLuLe, or IL wIII be dumuged
(suIpIuLed) und become useIess. SLop usIng u buLLery
beIore IL Is IuIIy dIscIurged. I LIere Is u probIem wILI
LIe wInd generuLor, LIen cIurge LIe buLLery Irom unoLIer
source wILIIn Lwo weeks.
CIurgIng LIe buLLery Loo Iurd wIII uIso dumuge IL. AL
IIrsL, wIen LIe buLLery Is dIscIurged, IL Is suIe Lo use u
IIgI currenL, buL IuLer LIe currenL musL be reduced or
LIe buLLery wIII overIeuL und LIe pIuLes wIII be dumuged.
TIe besL wuy Lo IuIIy cIurge u buLLery Is Lo use u smuII
currenL Ior u Iong LIme.
WuLcI LIe buLLery voILuge. I LIe buLLery voILuge Is beIow
11. voILs, LIen IL Is beIng dIscIurged Loo mucI. I LIe
voILuge Is IIgI (over 1q voILs) LIen LIe buLLery cIurgIng
currenL Is Loo IIgI. Use Iess currenL or more currenL In
LIe Iouds Lo correcL LIese probIems. I LIere Is no
voILmeLer uvuIIubIe, LIen LIe user sIouId wuLcI LIe
brIgILness oI LIe IIgILs und IoIIow LIese ruIes: -
DIm IIgILs meun Iow buLLery. Use Iess
eIecLrIcILy!
Very brIgIL IIgILs meun Loo mucI
wIndpower. Use more eIecLrIcILy!
A good wuy Lo use more eIecLrIcILy Is Loo
cIurge more buLLerIes In wIndy weuLIer,
perIups cIurgIng buLLerIes Irom neIgIbours'
Iouses.
TIere ure sImpIe eIecLronIc cIrcuILs desIgned
Lo reguIuLe LIe buLLery voILuge uuLomuLIcuIIy.
TIey ure cuIIed 'Iow voILuge dIsconnecLs' und
'sIunL reguIuLors'. I LIe user Is noL wIIIIng Lo
wuLcI LIe buLLery voILuge, LIen IL Is necessury
Lo IIL u dIsconnecL und u reguIuLor.
;I-*( )%/-"#(+) 5.)5-.(
TIe dIugrum sIows u sImpIe 1z-voIL cIrcuIL. L
Is desIgned Lo swILcI Iouds on und oII ('sIunL'
or 'dump' Iouds). L cun uIso be used Lo
dIsconnecL user Iouds In LIe evenL oI Iow buLLery voILuge.
or u 1z-voIL mucIIne you wouId need Lwo oI LIese
cIrcuILs, und q 1o ump Iouds Lo reguIuLe LIe cIurge
ruLe.
A good uILernuLIve wouId be Lo buy u Truce C-qo
conLroIIer. TIIs Ius PWM swILcIIng on one bIg Ioud, und
IL Ius Lwo buLLery cIurgIng ruLes.
:.&( +L 5+2F+*%*(& )%X-.)%$
C duuI opump M1q8
TrunsIsLor TP1z1 or 1zo
VoILuge reguIuLor qV1oomA
PreseL poLenLIomeLer 1oK cermeL
PreseL poL ooK cermeL
ResIsLors 1oK o.zW
ResIsLors 1ooK o.zW
ResIsLors 1K o.zW
DIodes 1A
ndIcuLors ED 1zV
CupucILors 1ooou 16V
ReIuys 1zV 16A
OPAMP
RELAY
COIL
0V
2
3
8
1
100K
C
B
E
'+12V'
10K
TERMINALS
LED
10K
OPAMP
RELAY
COIL
6
5
4
7
100K
C
B
E
10K
LED
1,000UF
10K
TIP121
TIP121
RLY 1
RLY 2
9V REG. IN OUT
10K
10K
10K
10K 10K
10K
0V
COM
100K
100K
TIP121
BCE
7809
IN C OUT
DUMP LOAD
DUMP LOAD
-
BATTERY NEGATIVE
FUSES
BATTERY
POSITIVE
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 PB
!'6:H?I"8+(6#(5*JI"J'K
1?(56 >")A7?%78 87?(5
PoIyesLer Is LIe pIusLIc subsLunce used In IIbergIuss work
Ior buIIdIng bouLs, cur body purLs, eLc. VurIous LIIngs
ure udded Lo IL Lo muke IL work beLLer Ior vurIous jobs.
TuIk Lo your suppIIer und expIuIn wIuL LIe resIn Is Lo be
used Ior. Your suppIIer sIouId be ubIe Lo IeIp you.
Hardeners
TIere ure Lwo sysLems used Lo Iurden poIyesLer resIn,
und eucI sysLem uses Lwo cIemIcuIs. or resIn cusLIng
und mosL IIbergIuss work we use peroxIde und cobuIL.
('Cur body IIIIer pusLes' use LIe oLIer sysLem.)
CobuIL 'ucceIeruLor' Is u purpIe IIuId. Your suppIIer wIII
mIx LIe rIgIL umounL oI cobuIL InLo LIe resIn. AILer IL Is
mIxed, LIe resIn musL be sLored In LIe durk, or IL wIII
Iurden.
PeroxIde 'cuLuIysL' Is u Iuzurdous cIemIcuI. AvoId
conLucL wILI skIn. SLore In u PVC conLuIner, In LIe durk,
beIow z degrees C. Never mIx IL wILI cobuIL (excepL Ior
LIe cobuIL uIreudy In LIe resIn), or IL wIII expIode. MIx
very smuII quunLILIes (ubouL 1-z%) oI peroxIde wILI resIn
or IL wIII overIeuL.
Wax-free 'Air inhibited' resin ' B'
TIIs Lype oI resIn Is used Ior 'geI-couLs' on bouL mouIds,
wIere LIe resIn Is goIng Lo be buIIL up In sLuges. We do
noL recommend usIng LIIs resIn Ior LIe uILernuLor
cusLIngs. Any exposed surIuce wIII remuIn Lucky
IndeIInILeIy. Ask Ior resIn 'A', or beLLer sLIII 'cusLIng
resIn'.
Thixotropic additive
A specIuI powder oI very IIgIL sIIIcu Is oILen udded Lo
resIn Lo muke IL LIIcker, so LIuL IL Is eusIer Lo spreud IL
wILI u puInLbrusI. TIIs powder Is noL needed Ior cusLIng
resIn. I IL Is uIreudy udded, IL does no Iurm.
Styrene monomer
ApproxImuLeIy % oI LIe resIn us suppIIed Is sLyrene
monomer. TIIs Is used Ior LIInnIng LIe resIn. L cuuses
LIe smeII. L Is possIbIe Lo udd u IILLIe more sLyrene
monomer (1o%) Lo muke IL more IIquId II desIred.
Pigment
PIgmenL cun be used Lo coIour LIe cusLIng, II u coIoured
IInIsI Is desIred. Add pIgmenL Lo LIe IIrsL mIx, wIIcI
wIII be on LIe ouLsIde oI LIe cusLIng. Add no more LIun
1o% pIgmenL Lo LIe mIx. L Is noL necessury Lo udd
pIgmenL Lo LIe resIn. WILIouL pIgmenL, LIe cusLIng Is
LrunspurenL und LIe coIIs ure vIsIbIe.
Fiberglass
TIe resIn Ius uImosL no sLrengLI wILIouL IIbergIuss. L Is
uvuIIubIe In sIeeLs oI 'cIopped sLrund muL' (CSM). L Is
uIso possIbIe Lo buy IIbergIuss cIoLI. TIIs Is useIuI Ior
LIe mugneL roLor cusLIngs. Add u IILLIe resIn Lo LIe
IIbregIuss, und press ouL uII LIe uIr bubbIes, beIore
uddIng more resIn.
Talcum powder
TuIcum powder Is u cIeup IIIIer LIuL cun be mIxed wILI
LIe resIn uILer LIe peroxIde Ius been udded. L mukes
LIe resIn mIxLure mucI cIeuper, und u IILLIe LIIcker.
ResIn cun be mIxed wILI up Lo LwIce ILs own weIgIL oI
LuIcum powder. TIe powder uIso reduces LIe IeuL buIId-
up In Iurge resIn cusLIngs.
B+-"$ F)%F#)#(.+*
Polyurethane varnish
OrdInury puInL sIouId noL be used on mouIds. BeLLer Lo
use noLIIng. I possIbIe, use poIyureLIune vurnIsI. TIIs
wIII prevenL moIsLure comIng ouL oI u mouId mude Irom
wood, pIusLer or cIuy. SmooLI LIe vurnIsI oII wILI
sundpuper beIore poIIsIIng IL.
Polish
PoIIsI LIe mouId severuI LImes beIore usIng IL IIrsL LIme.
Rub uII LIe poIIsI oII wILI u rug und LIen Ieuve IL some
Iours und do IL uguIn. SIIIcone poIIsI Is noL compuLIbIe
wILI PVA reIeuse ugenL. Use wux poIIsI.
PVA Release agent
MouIds LIuL ure used muny LImes wIII beneIIL Irom PVA
reIeuse ugenL. PuInL LIIs over LIe mouId beIore eucI use,
und IeL IL dry. L Iorms u sIeeL oI PVA, wIIcI greuLIy
IeIps Lo sepuruLe LIe cusLIng Irom LIe mouId.
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 PD
!'6:H?I"8+(6#(5*JI"J'K
N=+)) =+I:(57
?'>>)7=75%
!"#$%&
Curve LIe bIudes In LIe
sume wuy us LIe Iurger
mucIIne bIudes buL
wILIouL LIe wedges.
TIese bIudes ure sIorLer
und sLubbIer.
DImensIons In ncIes
station width drop thickness
1 6 0 1 15/16
2 6 1 3/4 7/8
3 3 15/16 3/4 9/16
4 3 1/8 3/8 3/8
5 2 9/16 1/4 5/16
6 2 3/16 1/8 1/4
DImensIons In mm
station width drop thickness
1 153mm - -
2 153mm 45mm 22mm
3 100mm 19mm 14mm
4 80mm 10mm 10mm
5 65mm 6mm 8mm
6 55mm 3mm 6mm
TIe Iub needs u IoIe LIrougI IL Lo IIL over LIe beurIng
IousIng.
!%#).*/ I-H
Use u beurIng Iub Ior u LruIIer Ior LIe smuII mucIIne.
You cun buy LIese In LIe UK Irom www.Lowsure.com
*%#-3+%&)
\+<-) *%#-3+%& _-!N#5 C+%/A I%&&
1
sIuIL
SLeeI pIpe
1 " overuII
11 Jq"
|zoo mm|
1 " |z.q|
overuII
1J8"
| mm|
z
sIeeve
SLeeI pIpe
1 " nomInuI
bore
1 1Jz"
|8mm|
1 1Jq"
|.q|
overuII
1J8"
| mm|
LIIck
1
sIeeve
SLeeI pIpe
1 " nomInuI
bore
1Jz"
|1qo mm|
1 1Jq"
|.q|
overuII
1J8"
| mm|
wuII
z
yuw &
LuII
beurIng
SLeeI pIpe
1 " nomInuI
bore
6"
|1o mm|
1 1Jq"
|.q|
overuII
1J8"
| mm|
wuII
1
LuII
boom
SLeeI pIpe
1 " nomInuI
bore
18"
|oo mm|
1 1Jq"
|.q|
overuII
1J8"
| mm|
wuII
z SLeeI pIpe
1 1Jq"
nomInuI bore
"
|1o mm|
1 J8"
|qz.z|
overuII
1J8"
| mm|
wuII
1 SLeeI dIsk q" |zo|
mInImum
1Jq"
|6 mm|
\+-,-) *%#-3+%& _-!N#5 I+;#5 U5+,X
1 SLeeI pIuLe z"
|1oo|
1 1J8"
|6 mm|
J8"
|1o mm
1 SLeeI bur 8" |zoo| 1 1Jz"|o| J16' |8
RADIUS
0
4"
[100]
8"
[200]
12"
[300]
16"
[400] 20"
[500]
24"
[600]
DISK DIAMETER 8"[200]
(INTERNAL 2.5")
TIP CHORD
2 3/16 [55]
BEARING HUB
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 PP
!'6:H?I"8+(6#(5*JI"J'K
und In LIe USA Irom
ILLp:JJwww.souLIwesLwIeeI.comJLruIIpurLsJIubsJIubs.
ILm
4I% &I#L(
TIe IoIIow sIuIL Is one IncI overuII dIumeLer. TIIs
Ieuvy wuII Lube muy be Iurd Lo IInd. Iuve some II you
need IL. Use u 11 Jq" |oomm| IengLI.
We cuL sIeeve pIeces Lo IIL over LIe sIuIL. 1" bore pIpe
Is good Ior LIIs purpose.
AL LIe sLuLor end oI LIe Lube we cuL u noLcI Jq" deep so
LIuL LIe wIrIng Irom LIe sLuLor cun enLer LIe Lube und
run buck LIrougI LIe mIddIe oI LIe beurIng.
WeId on u sIeeve pIece 1 1Jz" |qomm| Iong. L ends IIusI
wILI LIe Iuce oI LIe sLuLor cusLIng.
BeLween LIe sLuLor und LIe beurIng Iub we used u spucer
sIeeve ubouL 1 Jq" |qmm| Iong. TrIuI und error wIII
IeIp In sIzIng LIIs spucer. SIzes wIII depend on LIe
LIIckness oI LIe bIude rooLs Ior exumpIe.
BeIInd LIe Iub
Is unoLIer sIeeve,
wIIcI resLs
uguInsL LIe
beurIngs. TIIs
cIumpIng sIeeve
uIso Iorms purL
oI LIe supporLIng
Irume oI LIe
wInd generuLor
(see IuLer).
DrIII LIe wIeeI sLud IoIes ouL Lo 1zmm. TIe US Iub's
wIeeI sLud IoIes ure jusL over 1Jz" In dIumeLer buL LIe
bore Is neur enougI Lo suIL LIe 1Jz" uIILIreud.
TIe sLeeI dIsk uL LIe buck oI LIe mugneL roLor Is 1Jq"
|6mm| LIIck und q" |zomm| overuII. L Ius u IoIe In
LIe cenLre 1 1Jz" In dIumeLer. None oI LIese dImensIons
Is crILIcuI.
TIe Iour mounLIng IoIes In LIe sLeeI dIsk
Iuve Lo be Lupped Lo receIve LIe ends oI
1Jz" |M1z| uIILIreud sLuds. TIere Is no
room Ior nuLs In LIIs mugneL IuyouL. A
smuIIer sLud dIumeLer wouId work equuIIy
weII II IL IILs LIe wIeeI sLud IoIes.
9+(+) 2+-"$.*/
TIe mugneL roLor Is mouIded In LIe sume
wuy us In LIe bIg mucIIne. Use u mugneL
posILIonIng jIg Lo IocuLe LIe mugneLs.
TIey uILernuLe norLIJsouLIJnorLI. No
Index murks ure needed Iere. Keep LIe
cenLruI purL cIeur oI resIn, und sLop resIn
Irom goIng InLo LIe LIreuded mounLIng
IoIes.
9 / 1 6 "
BLADES
HUB
MAGNET ROTOR
STATOR
3 1/2"
1 1/2" 3/4"
2 1/4" 1 3/4"
STATOR
SPACER
BETWEEN BEARINGS
NOTCH
DEPTH
3/8"
ALLTHREAD
AND TWO
NUTS
1/2"
ALLTHREAD
3/8"
ALLTHREAD
AND TWO
NUTS
1" O.D. TUBE
ENDS HERE
5 1/2"
1" NOMINAL BORE PIPE SLEEVE
THREE
WIRES
NOTCH
DEPTH
3/4"
N4L0-M.UT ^-4, MY
P` /-U@4042
@UL!-.4
HUB
FLANGE
SHOWN
SHADED
BLADE
ROOT
1/4"
PLYWOOD
DISK
CUT
AWAY
NOTCH
WELDED
SLEEVE
SPACER
SLEEVE
CLAMPING SLEEVE
SHAFT
NOTCH
MAGNETS
2" x 1" x 1/2"
1/4" STEEL PLATE
9" OVERALL
DIAMETER
MOUNTING
HOLES 1/2"
[M12]
AT 4" PCD
MAGNET ROTOR
EDGE OF
POLYESTER
CASTING
9.5" O.D.
46 x 30 x 10
240mm
230mm
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 PQ
!'6:H?I"8+(6#(5*JI"J'K
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 PR
!'6:H?I"8+(6#(5*JI"J'K
;(#(+) 2+-"$
TIe sLuLor oI LIe smuII mucIIne musL be mouIded Lo LIe
sIuIL squureIy. WIen LIe sLuLor Is IorIzonLuI LIe sIuIL
musL be verLIcuI. You Iuve Lo be uccuruLe or LIe mugneLs
wIII noL be ubIe Lo come cIose LIe sLuLor oI LIe ussembIed
mucIIne und LIe ouLpuL wIII be Iow.
TIe sLuLor mouId Ius u 1" IoIe uL LIe cenLre LIrougI
wIIcI LIe sIuIL musL puss. IrsL weId on LIe coIIur uL LIe
sLuLor end oI LIe sIuIL und LIen drop LIe 1" sIuIL LIrougI
LIe IoIe. TIe sIuIL wIII uIso puss LIrougI u second IoIe
In unoLIer bourd beIow LIe mouId. TIe second bourd
keeps LIe sIuIL squure Lo LIe sLuLor mouId durIng LIe
cusLIng process.
To seL up LIe sLuLor mouId you Iuve Lo IIrsL screw u
coupIe oI wooden joIsLs (z x q's) onLo LIe busebourd.
TIen IIL LIe sIuIL. Move LIe sIuIL uround unLII IL Is
precIseIy squure Lo LIe mouId und LIen screw LIe mouId
Lo LIe joIsLs.
'&&%2H"1 +L (I% &(#(+)
SoIder LIe coIIs LogeLIer uccordIng Lo LIe
dIugrum on LIe rIgIL. Tuke greuL cure Lo
ensure LIuL none oI LIe coIIs ure upsIde
down. TIe wIre sIouId uIwuys run
cIockwIse Irom LIe sLurL Lo LIe IInIsI (or
uIwuys LIe oLIer wuy, buL no mIxIng oI coII
roLuLIons).
BrIng LIe IIexIbIe sLrunded wIres ouL
LIrougI LIe noLcI In LIe sIuIL und rIgIL
down LIe IoIIow sIuIL Lo LIe oLIer end.
rom LIere LIey wIII uLLucI Lo Iurger wIres
IeudIng Lo LIe ground und LIe recLIIIer uL
LIe buLLery.
Remove LIe wIred up coII ussembIy und sIuIL cureIuIIy
Irom LIe mouId. SLurL LIe cusLIng In LIe usuuI wuy wILI
pIenLy oI poIIsI und LIen uppIy weL resIn und u dIsk oI
IIbregIuss Ior sLrengLI. RepIuce LIe coIIs und sIuIL InLo
LIe mouId. Pour on resIn mIxed wILI LuIcum powder.
AppIy more IIbregIuss Lo LIe upper sIde und LIen cIump u
IId down onLo LIe coIIs Lo press LIem IIrmIy InLo LIe
mouId (excepL rIgIL uL LIe cenLre).
AL LIe cenLre uround LIe sIuIL, udd pIenLy oI very LIIck
mIx und IIbregIuss Lo muke u sLrong uLLucImenL beLween
sLuLor und sIuIL.
JOIST
JOIST
BASE
VERTICAL
STATOR MOULD
1
2
3
4
5
6
COIL CONNECTIONS
'SERIES STAR'
START 1= START 2 = START 3
FINISH 1 = START 4
FINISH 2 = START 5
FINISH 3 = START 6
FINISH 4 = OUTPUT
FINISH 5 = OUTPUT
1
2
3
4
5
6
L"()
I"557I%("5?
COILS CONTAIN
85 TURNS OF #16 WIRE [1.4mm] ON A 3/8"[11mm] FORMER FOR 12V
OR 170 TURNS OF #20 [0.8mm]WIRE ON A 5/16" [8mm]FORMER FOR 24V
OVERALL DIAMETER
HOLES IN COILS MUST MATCH
MAGNETS ON ROTOR
STATOR DIMENSIONS
HOLE
COIL
THICKNESS
DEPEND
ON THE
WINDING
CHOSEN
2 -1/2 "
2"
3 1/2 "
5"[130]
9"[224]
10 1/2"[264]
86mm
70mm
46mm
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 PZ
!'6:H?I"8+(6#(5*JI"J'K
4I% 1#G H%#).*/
TIe yuw beurIng consIsLs oI u verLIcuI 1" pIpe InserLed
InLo u 1 1Jq" pIpe (jusL IIke LIe IncIIned IInge LuII
beurIng). TIIs works ouL IIgILer LIun LIe 1 1Jz" yuw pIpe
we used Ior LIe Iurger mucIIne.
TIe yuw beurIng supporLs LIe sIeeve Ior IoIdIng LIe buck
end oI LIe sIuIL. TIIs Is LIe sIeeve we reIerred Lo eurIIer.
We weIded Lwo nuLs Lo LIe Lop oI IL so we couId screw
down und cIump LIe sIuIL. We cuL u noLcI Ior LIe wIres
Lo exIL LIrougI LIe boLLom uL LIe reur end.
We weIded LIIs sIeeve onLo u pIece oI J8" LIIck pIuLe.
We puL u 1 1Jz" IoIe LIrougI LIe pIuLe Ior wIrIng down
LIe Lower. TIen LIe pIuLe goL weIded onLo LIe Lop oI LIe
yuw beurIng. TIe spuce beLween LIe yuw beurIng cenLre
IoIe und LIe sIuIL cenLre Is 1 J8". TIIs Is LIe IurIIng
oIIseL oI LIe mucIIne.
4I% (#." H%#).*/ #*$ (#."
TIe LuII IurIIng sysLem Is uImosL exucLIy IIke LIuL Ior LIe
Iurger mucIIne. However LIe sIzes ure smuIIer. TIe LuII
IInge beurIng uses pIpe sIzes exucLIy LIe sume us LIe yuw
beurIng:
" Iong ouLer pIpes
In 1 1Jq" pIpe
und 6" Iong Inner
pIpes In 1" pIpe
TIe Inner pIpe Is weIded Lo u
pIece oI LIIck pIuLe wILI u zo
degree ungIe on IL jusL us In
LIe cuse oI LIe Iurger versIon
buL LIe pIuLe Is onIy IuII LIe
sIze.
IrsL weId LIe sLeeI pIuLe onLo
LIe sIde oI LIe 1" x 6" pIpe.
TIen weId LIe oLIer edge oI
LIe sLeeI pIuLe Lo LIe sIde oI
LIe yuw beurIng.
TIe IInge mukes u zo-degree ungIe Lo LIe
verLIcuI. Seen Irom ubove LIe IInge mukes
u -degree ungIe Lo LIe uxIs oI LIe
uILernuLorJbIudes sIuIL.
TIe ouLer purL oI LIe IInge Is u 1 1Jq" x "
pIpe LIuL sIIdes over LIe 1" pIpe. You need
Lo weId u pIuLe ucross LIe Lop end so IL
Lurns IreeIy. TIe LuII ILseII Is u pIece oI pIpe
18" x 1" weIded Lo LIe ouLer pIpe oI LIe
IncIIned IInge. WIen you Iuve weIded LIe
1"
1/4"
6"
2"
20
degrees
REAR VIEW
YAW
BEARING
TAIL HINGE
INNER PIPE
SHAFT
CLAMP
6"
5 "
TOP VIEW
YAW
BEARING
CLAMP
55 deg
1 5/8"
3/8" PLATE
1/2" HOLE
1/2" SCREWS
1" BORE PIPE
3/8" PLATE
1/2" HOLE
1" PIPE
1 1/4 " PIPE
1" PIPE
YAW
BEARING
1/2" SCREWS
1" PIPE
SLIDES INSIDE
1 1/4" PIPE
NUT
WELDED
ON
SDE VEW AND TOP VEW
OI TA HNGE NNER PPE
!"# %" &'()* + #(5* 67578+%"8 9 %:7 +;(+) <)'; +)%785+%"8 #(5*=()) >)+5? 9 @+A BCCD E78?("5 F !'6: G(66"%% >+67 PS
!'6:H?I"8+(6#(5*JI"J'K
LuII onLo LIe IInge you cun seL IL up on LIe Inner pIpe
und work ouL Iow Lo cuL LIe noLcI. TIe noLcI uIIows
LIe LuII Lo swIng LIrougI ubouL q degrees Irom LIe Iow-
end posILIon up Lo neurIy puruIIeI Lo LIe bIudes.
WIen LIe noLcI Ius been cuL und LIe LuII swIngs nIceIy
you cun udd LIe 'T pIece' on LIe end und IIL LIe vune.
TIe T sIouId be verLIcuI In LIe normuI (Iow-end)
posILIon oI LIe LuII. WeId IL on IIusI by cuLLIng u noLcI
InLo LIe pIpe IIrsL. suggesL u T mude Irom 1z" x 1" x
1Jq" bur. TIe vune cun be mude Irom ubouL 18" x 1z" x
1Jq" pIywood.
C.).*/ -F (I% H#((%)1
TIe besL wIrIng sysLem Is Lo Luke uII LIree wIres Irom
LIe wInd LurbIne Lo LIe IocuLIon oI LIe buLLery.
ConnecL LIem IIrsL Lo u bruke swILcI. You cun use LIIs
Lo sLop LIe wInd LurbIne. A Lwo-poIe on-oII swILcI ruLed
Ior zoA uL 1z voILs DC Is suILubIe Ior u 1z voIL sysLem.
rom LIe swILcI, Ieud LIe wIrIng on Lo LIe recLIIIer und
connecL uny AC wIre Lo uny AC LermInuI. You wIII need
Lwo brIdge recLIIIers Lo provIde enougI AC LermInuIs.
ConnecL boLI neguLIve LermInuIs Irom LIe brIdge
recLIIIers Lo buLLery neguLIve und connecL LIe posILIves Lo
buLLery posILIve vIu u suILubIe Iuse.
TAIL
VANE
18"
5"
ALTERNATOR
AND BLADES
0. 2787"
80
degrees
LOW END POSITION
HIGH END
TAIL ARC OF
MOVEMENT
2-POLE
SWITCH
FOR
BRAKING
3 WIRES
FROM
WIND
TURBINE
AC
AC
AC
+
+
FUSE
+
BATTERY
RECTIFIERS
WIRING FOR SMALL WIND TURBINE
TOP VEW