Introduction

Building a wind generator can be an affordable and effective way to generate electricity, especially for those in remote areas or off-grid situations. This guide will walk you through the process of constructing a wind generator for under $100, using both scavenged and purchased components. We’ll cover the design, assembly, and maintenance of the generator, as well as tips for ensuring its durability and efficiency.

Design and Components

Key Components

  • DC Motor: Purchase a DC motor for $40. This will serve as the generator.
  • Blades: Construct three blades using wood and fiberglass. Each blade should be 24 inches in diameter.
  • Hub: Purchase a hub for $5 to attach the blades to the motor.
  • Tower: Use a 1.5-inch diameter steel tube mast for stability. The mast should be assembled in three sections.
  • Miscellaneous Hardware: Include screws, nuts, and bolts for $13.

Design Elements

  • Generator: A 12V DC generator with a 30A output.
  • Blades: Three-blade propeller with a 24-inch diameter.
  • Mounting: Use a 1.5-inch diameter steel tube mast.
  • Guy Lines: Three 10-foot guy lines for stability.

Performance Metrics

  • Windspeed Range: The generator operates effectively in 5-25 mph winds.
  • Output: Produces 12-15 amps at 15 mph.
  • Battery Charging Time: Charges 12V batteries in approximately 3 hours at 20 mph.

Assembly Process

Step 1: Assemble the Mast

Cut the steel tube into three sections. Weld the sections together to form the mast. Ensure the mast is straight and secure.

Step 2: Attach the Blades to the Hub

Sand the wood blades to ensure a smooth surface. Apply fiberglass reinforcement to the blades for added strength. Attach the blades to the hub using screws and nuts.

Step 3: Mount the Generator to the Mast

Attach the generator to the top of the mast using bolts and nuts. Ensure the generator is securely fastened and aligned with the blades.

Step 4: Install Guy Lines

Attach the guy lines to the mast using stainless steel hardware. Ensure the guy lines are evenly spaced and securely fastened. Add 300+ lbs of ballast to the base of the mast for stability.

Step 5: Connect to Battery Bank

Connect the generator to a charge controller. Connect the charge controller to the battery bank. Ensure all connections are secure and properly insulated. Test the system to ensure proper operation.

Wiring the System

Connect the DC motor to the charge controller. Connect the charge controller to the battery bank. Ensure all wiring is properly insulated and secured. Test the system to ensure proper operation.

Battery Maintenance

Regularly check the battery bank for signs of corrosion or damage. Use a battery desulfator to extend the life of the batteries. Ensure the battery bank is properly ventilated to prevent overheating.

Tips and Warnings

  • Durability: Test the generator in various climates to ensure durability.
  • Protection: Protect the generator against high winds by using guy lines and ballast.
  • Materials: Use stainless steel hardware to prevent corrosion.
  • Scale Up: Consider using larger blades for higher output.
  • Weatherproofing: Add weatherproofing to the generator for long-term use.

Summary

Building a wind generator for under $100 is a cost-effective way to generate electricity. By following the steps outlined in this guide, you can construct a durable and efficient wind generator using both scavenged and purchased components. Regular maintenance and proper assembly will ensure the generator operates effectively and safely.

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