Good luck. What were going to do now is mark where we will cut of the wire rod. The first picture is a view from the bottom disk. I put 2 bolts there and they will rest on the bottom bearing. I left the wire longer there so i can connect a generator of some sort there. The upper disk is the second picture and the rod will be cut shorter. On that side we will only have a bearing to balance the turbine when its in place on its frame.
If you have a lathe this is a pretty straight forward job. I made the rod 10 mm thick on both sides. The pictures show the bottom side of the wire rod. Make sure it fits nicely because this will determine how smooth your turbine will run. The bearing i used is made out of 3 parts as shown on the first picture. This bearing is made to cope with vertical weight.
If you watch closely you will see that the 2 disks don't have the same inner size hole. The disk with the biggest hole the one on the right is the top part of the bearing where the turbine will rest on.
I cut the hole out on the lathe just the diameter of the bearing. Do this according to the size of the bearing you will use. Don't make the hole to deep! Make sure that the top part of the bearing is just sticking out of the holder.
The reason for this is that the top ring will spin together with the turbine and would otherwise rub against the inside of the holder and would slow your turbine down and wear it out quickly. You will also have to drill a hole through the bottom of the holder so the wire rod can fit through. Make it slightly bigger then the size of the rod so ones its mounted it will not tough the sides. You have seen that this bearing has no grease in it so we will have to install a grease nipple.
Use a thread cutting tool to do so. First drill a hole according to the tread and the nipple size you will use. Mine was M6. Use some cutting oil because your cutting in aluminium and otherwise it will get all rough on the inside. Run the cutting tool for about 1 turn and then run it back for half a turn.
This way the metal is cut inside and you will not brake your tool. Use the 3 stages of cutting till you reach the right tread. First you get two pieces of wood that are exactly the same length. Make sure they are wide enough so you can make a strong structure. Look for the center of both of them and make a hole the size of the bearing holder for the bottom one and the size of the top bearing for the top one.
I was lucky i had a big drill to do so. If not take your biggest drill bit and drill it out and then cut the rest out with a round axe. For the bottom one you have to drill the center of the hole trough with a drill one size bigger then the size of the big wire rod that will fit into the bearing.
For the bottom one you will have to cut out a little slot so the nipple can fit inside and that you have enough space to put in the grease pump. You can see what it should look like on the pictures. Take two more straight pieces of wood for the sides.
I had some plywood so i used that Take the bottom piece with the bearing holder inside and put it on a flat surface. Use one of the side pieces and screw it on there. First drill some holes in the side so the screws will go in better.
Make sure its perfectly square. Now take your turbine thats completely assembled and lower it into the bottom bearing. Now you take the top piece and slide the bearing over the big rod. Measure on both sides of the turbine and make sure you measure the same distance, that way your frame will be perfectly square. Search for:. Free Double helix wind turbine design.
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