Wheel
Blades
Chuck
Generator
Strut & Fin
Slip Ring
Mounting
Charge Controller
Battery
General
Steps/Assembly
Parts List
|
Contact |
|
|
Steps
Assembly Instructions- Obtain a bicycle wheel
- Remove the axle.
- Pop the bearing cover off.
- Remove the bearings.
- Clean away the grease.
- Insert bolt/washers
- Paint chuck
- Oil chuck (reduce weather effects to come)
- Add chuck
- Cut away half of the pairs of spokes
- True the wheel (spoke wrenches can be helpful)
- Paint the rim to fend off rust
- Apply vinyl for blades
- Connect wheel to the axle of another bike wheel for balancing (glue can be helpful)
- Mount fin to strut (using glue or other means to hold in place)
- Place wheel/chuck onto generator shaft
- Mark chuck and shaft (to be able to always use same orientation in the future)
- Place wheel/chuck/generator onto strut
- Move generator to a point that feels right for distance of wheel from the end of strut
- Mark location of generator on strut
- Find the center of gravity of that entire assembly and mark it
- Remove wheel from generator for now
- Drill hole in strut for flange bearing (a little bit toward the wheel to be slightly heavier on the fin side)
- Assemble bearing unit
- Glue audio jack inside the 3/8" nipple
- Attach bearing assembly (with the audio jack/plug for slip ring ready) to strut (JB Weld epoxy for example, good stuff)
- Mount generator to strut
- Connect wires
- Add grease inside chuck (reduce weather effects to come)
- Re-attach wheel to generator (trued and balanced)
- Mount assembly onto pole (connecting the wires)
- Stand back and marvel at what you've built :)
- Measure open-ciruit voltage with wheel spinning (wind blowing)
- Measure battery voltage
- Connect wires to charge controller and battery
- Measure voltages again
- Allow some charging and measure voltages again