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Follow the web link below. |
SPANISH click on link below |
Please contact Antonio and Beatrice direct by email. |
 Axial
flux plans now also available en Francais! |
CÓMO
CONSTRUIR UN GENERADOR EÓLICO |
Come costruire un generatore eolico TRADUZIONE
ITALIANA |
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"I was totally astounded to find your book in my mailbox yesterday. How it made it from deepest, darkest Scotland to deepest, brightest Arizona in four days I'll never know, but thanks for the fast service. The book appears to be excellent on a first skim, with brilliant diagrams. I'm looking forward to building one and adding it to our system (we live totally on solar power, seven miles from the nearest mains line). Cheers, Jonathan Hanson" This document has now superceded my old brakedrum windmill plans 
although the latter will still be of interest to some readers. The axial design is easier to build and involves less hunting around for parts. |
In recent years I have been developing construction techniques for axial flux alternators. In 2001, I made a construction manual available for free down load from this site. Since then I have taught a lot of courses and my ideas have moved forward. I have made the process simpler and I have made the alternator much more powerful by using neodymium magnets. You can see pictures of the construction process in action
during my
workshop courses by going to the pagesfor
the courses. There are two slightly different versions of the design - one using inches and one using metric measurements. Both are described in full in the plans. At the end of the document there are also plans for a three other sizes of wind turbine. LINKS There is a very nice new page at blueEnergy in August 2004 with pretty pictures of the US version being built. There is a lot of exciting new stuff going on at the Otherpower discussion board where Dan Bartmann is extending the design. Watch out for the photo diaries of his monday sessions. Dan Fink at Otherpower has also done a thoughtful page about the nitty gritty of the process, warts and all. |
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Bryan Thomas wrote: Hy Hugh. I just ordered your plans on how to build a wind turbine, and I had to type my credit card number with no spaces or no dashes in order for the Pay Pal order to work. I suggest that when you ask for the customers credit card number, you put, in parenthesis, (no spaces), just to avoid possible confusion, and also to avoid the possibility of missed sales. Keep up the good work on the good fight though and thanks for the reasonable price on the plans. |
PLEASE NOTE THAT ORDERS SENT BY SNAIL MAIL WILL NOT BE DEALT WITH UNTIL 20TH JANUARY AS I AM AWAY TO SOUTH AFRICA.Checks or money orders in poundsincluding postage in UK £12.00 GBP in Europe £13.00 GBP World £14.00 GBP Here is my address :
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Cash payments
including postage in UK £12.00 GBP Europe € 20 EUR World $30 USD If you want to pay with US$ or Euros,
please send
cash and not checks or money orders from overseas. UK cheques in
pounds are OK |
also now available from 
in the USA
and from CAT Mail Order: +44 (0)1654 705959 in the
UK
click here for a series of snapshots of the document (rather out of date), or read on for full details....
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I just finished your latest book. Damn, it's good. Great information and written very clearly. If you are ever near Denver Colorado and want to get a beer let me know. Sincerely. John Steele I have bought a copy of your axial flux design handbook and its a very interesting and educational book to read on how to build a wind power. I read it for a hundred times already learning on how the system works especially the mechanical side of the furling system and up to the electrical. Wow, its so nice of you to write something that detailed more especially on the construction of the blades. Going on the work from the construction of the blade I was really impressed on how the blade look like after I've finish one. The aerodynamic design was so fantastic. Best Regards, |
Received the Feb 2004 version of your windmill plans. I
have not
been able Oh well what can I say !!!!!!!!!! Jeff Reitz "I like the plans and the info, I really feel like I understand everything in it.... What I really liked was the way the "Little Pancake" machine was thrown in at the end. With just a couple of pages we have a complete constuction plan, once we know the principals. Reminds me of house plans, all you need is some drawings, notes, a good material list and someone to ask questions when you get stuck. " Ron Dinishak |
I ordered your wind turbine plans in January of
this year.
Well I have just put up the wind turbine and thought you would like a
picture.
It was my sons idea to write Got Wind on the vane.
Kindest regards, Gordon P.S. your plans are underpriced |
| Introduction 3 Blades 3 Alternator 3 Grid connection 3 Furling system 4 Units 4 Design decision: where to fit the rectifier 4 Some rules for adapting the design 4 8' [2.4m] machine construction - materials list 6 Notes on workshop safety 10 BLADE THEORY 11 Blade power 11 Blade speed 11 Blade number 11 Blade shape 11 Carving the blades 12 STEP ONE is to create the tapered shape. 12 STEP TWO carving the twisted windward face 12 Checking the drop 13 STEP THREE carving the thickness 13 STEP FOUR Carve the curved shape on the back of the blade 14 STEP FIVE Assembling the rotor hub. 15 Cutting the roots to 120 degrees 15 Marking and drilling the plywood disks 15 Clamping the blades together 15 Drilling holes for the mounting bolts 16 STEP SIX Cutting out and gluing on the wedges 16 ALTERNATOR THEORY 17 Preparing the bearing hub 18 Drilling out the 1/2' [12 mm] holes in the flange 18 Fabricating the alternator mounts 19 The Yaw Bearing 19 Alternator mounting bracket 19 Stator mounting brackets 20 Mounting the stub shaft/axle 21 Vauxhall / Opel hub 21 Trailer hub and stub axle 21 USA GM hub 21 Drilling the magnet rotor plates 22 |
Making the stator mould 23 Mark out the shape of the stator. 23 Cut out the stator shape in plywood. 24 Screw the mould to its base 24 Making the coil winder 25 ELECTRICAL THEORY 26 Winding the coils 26 Connecting the coils 27 Hints for soldering 27 Soldering the coil tails 27 The ring neutral 28 The output wiring 28 Casting the stator 29 Putting it together 29 Removing the casting from the mould 30 The magnet-positioning jig 30 Making the two rotor moulds 32 Parts of the moulds 32 Casting the rotors 33 Handling the magnets 33 Gluing the magnets to the disks 33 Dry run 33 Checking for magnet polarity 33 Preparation for casting the rotors 33 Putting it together 33 FURLING SYSTEM THEORY 34 Why furl? 34 How the furling tail works 34 Controlling the thrust force 35 Fabricating the tail hinge 36 The tail itself 37 Cutting out the tail vane 38 Mounting the rectifier box 39 Assembling the alternator 40 Preparation 40 Hub and shaft 40 Stator mounting holes 40 Back magnet rotor 40 The stator 41 Front magnet rotor 41 Connecting the rectifier 42 Testing the alternator 42 |
Short circuit tests 42 AC voltage tests 42 DC voltage tests 42 Connecting to the battery 43 Connecting the battery 43 Fuses or circuit breakers 43 Connections 43 Brake switch 43 Safety 43 Choosing suitable wire sizes 44 Wire type 44 Fitting and balancing the blades 45 Checking the tracking 45 Balancing the rotor 45 Fine tuning 46 Guyed tower ideas 47 Controlling the battery charge rate 48 Shunt regulator circuit 48 10 foot [3 metre] wind turbine 49 Wiring connections 49 12 foot [3.6m] wind turbine 50 The stator 50 Winding details 50 Wiring and connections 51 Magnet rotors (2 in number) 52 Alternator Mounts 52 Blade Dimensions 54 Making the plywood triangle 54 Tail hinge design 55 The moment of weight of the tail 56 4 foot [1.2m] diameter wind turbine 57 Blades 57 Bearing hub 57 The shaft 58 Rotor moulding 58 Stator mould 60 Assembly of the stator 60 The yaw bearing 61 The tail bearing and tail 61 Wiring up the battery 62 Using polyester resin 63 Mould preparation 63 Workshop tools 64 |
if you wish to grid connect this wind turbine, please check this link for more information
