Assemble Your Wind Turbine

• 1). Check with local plumbers or contractors for an appropriate piece of PVC pipe for your windmill blades. A scrap piece that fits your size requirements might be available for very cheap, if not free.
  
  
• 2). Saw the PVC pipe lengthwise into four equal parts using the table saw or jigsaw. Shape each part according to specifications of the design plan.
  
  
• 3). Grind and sand the edges of each PVC blade so they will be aerodynamic and smooth. Grind the trailing (straight) edge of each blade at a sharp angle to reduce wind friction.
  
  
• 4). Look for a piece of sheet steel or a hub shape at a junkyard or ask a contractor about scraps that will fit the needs of your design. A detailed template for shaping your own hub from scrap metal is featured in the book "Home Made Energy."
  
  
• 5). Bolt each of the blades to the hub using the steel bars to add stability and strength to the blade assembly.
  
  
• 6). Fix the blade assembly on a horizontal axis by its center hole and number the blades with a magic marker. Spin the blade assembly and note which blade finishes pointed down. Repeat this test 10 times, if one blade finishes in a downward position more than the others, it is likely heavier than the others. Balance the blade assembly by shaving off part of the steel connecting bar from the heavy blade.
  
  

Construct the Power System

• 1). Check with junkyards, contractors or constructions sites to collect the DC motor, a scrap of PVC to house the motor, the wiring you need for your electrical system, a steel pipe and a rotating joint to support the windmill.
  
  
• 2). Assemble the DC motor housing and windmill base according to your schematic and bolt the blade assembly to the motor axis.
  
  
• 3). Check with local businesses that use golf carts and forklifts to obtain "deep cycle" batteries. Companies that use these vehicles might give you their used batteries free of cost. Most batteries that are considered "dead" for commercial purposes can be refurbished using a desulfator. The "Home Made Energy" guidebook provides information on the number of batteries you'll require for the battery bank based on your power output needs.
  
  
• 4). Look for a used charge controller that you can obtain at minimal cost. A 45-amp charge controller is optimal. Set the charge controller to turn the current on and off when the charge of the batteries rises above or dips below a set voltage level. The best settings for these levels are 11.7v and 14.3v.
  
  
• 5). Solder or bolt your battery bank to the charge controller. Wire the DC motor from the windmill to the charge controller using a soldering iron or bolts.
  
  
• 6). Look for a used or inexpensive AC power inverter. Attach the AC inverter to the battery bank with solder or bolts. The inverter converts the direct current (DC) battery energy into alternating current (AC) used in plug-in electrical outlets. You can plug common home appliances directly into the AC inverter or wire it to your household electrical system.