Making A Wind Turbine Nose Cone
Making a nose cone for the Reaper wind turbine. Turned out great, but I think I might build a thermal vacuum former for doing this in the future. Just to speed things up. Check out the build article and get the plans: https://renewablesystemstechnology.com/project-blog/how-i-built-a-3-kw-off-grid-wind-turbine
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🛠 Build A DIY Wind Turbine Tower - Plans Available 📄
3 kW wind turbine plans: https://renewablesystemstechnology.com/3-kw-wind-turbine.html
Part 7 of the Reaper wind turbine series: in this video I build the tower for the new turbine. It consists of 30ft of 2.5" schedule 40 pipe, nearly 400ft of 3/16" galvanized aircraft cable attached with 3/8" turnbuckles and quick links, and four 600lb concrete ground anchors.
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How To Build An Off Grid Wind Turbine - 1000 Watts!
How To Build An Off Grid Wind Turbine. Check out this detailed step by step build article with downloadable plans to learn more: https://resystech.com/howtobuilda1kwwindturbine.html
Special thanks to all of my supporters, you guys rock!
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Fiberglass Wind Turbine Blade Vs Wood Blade
Check out my latest project: https://youtu.be/yXQnydST9fw
Fiberglass Wind Turbine Blade Vs Wood Blade: In this video I put the blades through a simple static load test using weights, to help demonstrate the superior strength of fiberglass wind turbine blades over wood blades. If you haven't seen them yet, you can check out the videos showing how these blades were made at the links below.
DISCLAIMER: this demo does NOT mimic the 'live' forces acting on a wind turbine blade during operation. That's what wind tunnels are for.
Reaper project details: https://www.renewablesystemstechnology.com/3-kw-axial-flux-hawt
Carving the wooden master blade:
http://bit.ly/BladeCarving
Casting the fiberglass blade:
http://bit.ly/FiberglassBlades
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Making Fiberglass Wind Turbine Blades
Check out my latest project: https://youtu.be/yXQnydST9fw
Check out the complete build video for the 3 kW Reaper turbine: https://youtu.be/EPmW-BjCiWI
Plans for the turbine are available here: https://www.resystech.com/3-kw-wind-turbine
Making Fiberglass Wind Turbine Blades - part 6 of the Reaper wind turbine build. In this video I cast fiberglass wind turbine blades for the turbine using DIY fiberglass molds (see link below for mold video). The blades were cast in two main pieces - a front shell and a back shell. Shear webs were installed along the length of the blade, and a wood core was installed in the hub mount. The two shells were then bonded together. The lay-up for each shell consists of 4 alternating layers of 7 oz fiberglass cloth and 2 oz fiberglass matt. The cloth layers were oriented so that the weave patterns were at 45 degrees to each other. The weight of the new fiberglass blade is ~9 lbs, the weight of the wood master blade is ~8 lbs. A link to a static load test video can be found below. Tower installation is next!
Reaper project details: https://www.renewablesystemstechnology.com/3-kw-axial-flux-hawt
Making the fiberglass molds:
http://bit.ly/FiberglassMolds
Static load test video:
http://bit.ly/BladeLoadTest
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Making Fiberglass Molds
Check out my latest project: https://youtu.be/yXQnydST9fw
Check out the complete build video for the 3 kW Reaper turbine: https://youtu.be/EPmW-BjCiWI
Plans for the turbine are available here: https://www.resystech.com/3-kw-wind-turbine
Making Fiberglass Molds - part 5 of the Reaper wind turbine build. In this video I make the fiberglass molds that will be used to form the blades and nose cone in the next video.
For the back blade mold I used 4 layers of 7 oz (200g) fiberglass cloth with 1/4"x3/4" wide plywood strips laminated between the last two layers for rigidity (each layer of fiberglass was oriented with the weave at 45 degrees to the previous layer). This seemed like overkill for a mold, so I switched to just 3 layers and plywood strips for the front blade mold. It worked out just fine.
I couldn't use wood strips on the nose cone (for obvious reasons), so for the first layer I used 2 oz (57g) fiberglass matt to make the cone rigid, then followed it with a layer of 7 oz cloth for strength.
FYI - fiberglass matt isn't as strong as fiberglass cloth. Fiberglass matt consists of oriented strands of fiberglass (almost similar to fiberglass insulation) and is typically thicker than fiberglass cloth of the same weight. Fiberglass cloth consists of weaved fiberglass strains that essentially 'lock' together and can be harder to work with around contoured surfaces. For these reasons, fiberglass matt is usually used to provide thickness and rigidity where needed, and fiberglass cloth is used for strength and flexibility.
I don't have a lot of experience working with fiberglass, so if any experts out there have some tips they'd like to share, please feel free.
Reaper project details: https://www.renewablesystemstechnology.com/3-kw-axial-flux-hawt
Lathe build video:
http://bit.ly/DIYLathe
Download the lathe plans:
http://bit.ly/LathePlans
Master blade video:
http://bit.ly/BladeCarving
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How To Build A Benchtop Lathe
How To Build A Benchtop Lathe. Get the plans:
https://renewablesystemstechnology.com/benchtop-lathe.html
Check out my latest project: https://youtu.be/yXQnydST9fw
I didn't have a lathe big enough, so I built one. This thing works great! If you haven't been following the Reaper turbine progress on social media, I intend to use this lathe to turn a foam model of the nose cone for the turbine rotor. The model will be used to cast a negative mold, and that mold will be used to cast the actual fiberglass nose cone. This will be covered in the next build video, along with the fiberglass blades and molds. Then it's just a matter of installing the tower and getting the turbine hoisted into the air. It's been a long project, that's for sure. Thanks for being so patient, folks! Plans for this lathe are available at the link below. Also, in case you haven't noticed, I've now enabled memberships for my channel. So if you like the content that I share on here and are interested in downloading plans for any of the projects or would just like to help contribute, then please consider signing up for a membership on Youtube or Patreon.
Once you're a member, you'll have access to all current and future plans published on resystech.com, at no extra charge. Just click the 'Join' button under this video, or check out the links below for more information. For those of you who are already members, I thank you so much for your support. You keep this adventure going, and I greatly appreciate it!
Download the plans:
https://renewablesystemstechnology.com/benchtop-lathe
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Build A Wind Generator - DIY Wind Generator - Hydro Generator - Off Grid Living!
Build A Wind Generator - DIY Wind Generator/Hydro Generator - Off Grid Living: https://renewablesystemstechnology.com/3-kw-wind-turbine.html
CHECK OUT MY NEW CYBER TRIKE BUILD: https://youtu.be/YMm3yrVhA88
Check out the complete build video for the 3 kW Reaper turbine: https://youtu.be/EPmW-BjCiWI
Making A Wind Turbine Generator - part 3 of the Reaper wind turbine build. In this video I mount the rotors and stators made in the previous videos, and do a quick bench test of the newly assembled axial flux permanent magnet generator.
I closed the air gap between the rotors as much as I dared to, and connected the stators in parallel after the rectifiers for more current (vs in series before the rectifiers for higher voltage, which is more efficient) to help protect my Classic 200 charge controller from voltage spikes until I get a clipper installed. I also need to upgrade the storage system from 24V to 48V in order to take advantage of the turbine full 4kW potential (the Classic 200 can only handle ~2kW on a 24V system, and 4kW on a 48V system). Regardless, the pmg is working good! Cut in rpm for 24V charging is ~100.
Hub and blades are next!
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Making Wind Turbine Stators: Vacuum Injection
Get the plans for this project here: https://renewablesystemstechnology.com/3-kw-wind-turbine.html
Learn how to design your own turbine from scratch: https://www.resystech.com/the-diy-wind-turbine-design-guide.html
Check out the complete build video for the 3 kW Reaper turbine: https://youtu.be/EPmW-BjCiWI
Making Wind Turbine Stators - part 2.5 of the Reaper wind turbine build. In this video I make the stators for the 4 kW axial flux Reaper turbine. Each stator consists of 12 coils with 75 turns of 14 awg wire each, and connected in star (wye) configuration. For more information about this project, visit the link below.
Drill Powered Coil Winder:
https://renewablesystemstechnology.com/coil-winder
Vacuum Injection Stator Mold:
https://renewablesystemstechnology.com/vacuum-injection-stator-mold.html
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Making Wind Turbine Magnet Rotors
Get the plans for this project here: https://renewablesystemstechnology.com/3-kw-wind-turbine.html
CHECK OUT MY NEW CYBER TRIKE BUILD: https://youtu.be/YMm3yrVhA88
Check out the complete build video for the 3 kW Reaper turbine: https://youtu.be/EPmW-BjCiWI
Making Wind Turbine Magnet Rotors - part 2 of the Reaper wind turbine build. In this video I make the four magnet rotors for the 3 kW Reaper wind turbine, as well as a jig for safely placing the magnets - as some of you know, handling magnets this powerful can be dangerous. Each rotor plate is 12" in diameter, and has 16 N50 2x1x1/2" neodymium magnets. For more info about this project, visit the link below. Part 3 is coming soon!
Modular Tool Guide Build Video:
http://bit.ly/ModularToolGuide
Modular Tool Guide Plans:
https://renewablesystemstechnology.com/modular-tool-guide-system
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🛠 Make A DIY Portable Drill Press - Plans Available 📄
Get the plans for this project here: https://renewablesystemstechnology.com/portable-drill-press.html
Check out my latest project: https://youtu.be/yXQnydST9fw
Learn how to make a portable drill press by downloading the plans at the following link:
https://renewablesystemstechnology.com/portable-drill-press
I needed a portable drill press for the next tool build for the Reaper project. The workshop is coming along great btw, should be back in business in a few days. If you're interested in the plans for this drill press, you can find them at the link below.
Drill Press Plans:
https://renewablesystemstechnology.com/portable-drill-press.
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Carving Cedar Wind Turbine Blades
Get the plans for this project here: https://renewablesystemstechnology.com/1-kw-axial-flux-hawt.html
Check out my latest project: https://youtu.be/yXQnydST9fw
Carving Wooden Wind Turbine Blades. I carved these blades from laminated red cedar last year (03/20/17) for the 1 kW axial flux wind turbine. Some of you have probably seen the original video already. However, due to copyright issues, I've had to re-edit and upload it again - sorry for the repeat.
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Building A Wind Turbine Frame
Get the plans for this project here: https://renewablesystemstechnology.com/3-kw-wind-turbine.html
Check out my latest project: https://youtu.be/yXQnydST9fw
Check out the complete build video for the 3 kW Reaper turbine: https://youtu.be/EPmW-BjCiWI
Building A Wind Turbine Frame - part 1 of the Reaper wind turbine build. In this video I build the frame for the 3 Kw axial flux 'Reaper' wind turbine. For more info about this project, visit the link below. Part 2 is coming soon!
Modular Tool Guide Build Video:
http://bit.ly/ModularToolGuide
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🛠 Build A Modular Articulated Tool Guide System
Get the plans for this project here: https://renewablesystemstechnology.com/modular-tool-guide-system.html
Check out the NEWER and BETTER version of this project: https://youtu.be/yXQnydST9fw
In this video I build a modular articulated tool guide for cutting and drilling magnet rotor plates and other steel components for micro wind turbines. Though my purpose is very specific, this guide system has a plethora of uses and would make the most out of any DIY'ers handheld power tool collection.
It consists of a simple table and a pair of articulated arms that can move a small power tool in a straight forward/reverse motion, and provide both vertical and lateral support while doing so. An adjustable strongback supports the arms at a desired height.
This guide system can be used with a variety of tools like an angle grinder, drill, small circular saw, or a trim router to create precision machines like a surface planer, chop/miter saw, drill press, drum sander, etc. The other great thing about this tool guide is the travel distance of the arm guides. For example, it has a cutting depth of up to 12” when used with an angle grinder. The arms can also extend a drill press beyond the table to allow drilling into long components such as table legs, spindles and posts, unlike conventional bench top drill presses where the fixed chuck is only a few inches from the support post and limits both the width and height of the material that can be drilled.
Download the plans:
https://renewablesystemstechnology.com/modular-tool-guide-system
Get Matthias Wandel's gear template generator:
http://woodgears.ca/gear
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11
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🛠 Build A DIY Vacuum Injection Mold
Get the plans for this project here: https://renewablesystemstechnology.com/vacuum-injection-stator-mold.html
Check out my latest project: https://youtu.be/yXQnydST9fw
In this video I build a vacuum injection mold for casting axial flux stators. The mold is made from flexible silicone rubber to make demolding the cast easier. It fits 12 coils (with up to 80 turns of 14 awg wire per coil), and forms a 5/8" (16mm) thick stator cast. I also built a degassing chamber for degassing resin (ie: removing air bubbles after mixing) and a resin trap to catch excess resin before it enters the vacuum pump and ruins it.
If you don't want to use vacuum injection or find it intimidating, then the mold can also be used conventionally too. Being made of HDPE and flexible silicone rubber, it can be used many times. A big step above regular 'one time use' wooden molds. Multiple molds could theoretically be connected to the vacuum system and cast simultaneously as well, to facilitate efficient mass production in a commercial setting if desired.
Download the plans:
https://renewablesystemstechnology.com/vacuum-injection-stator-mold
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34
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🛠 Make A DIY Coil Winder
Get the plans for this project here: https://renewablesystemstechnology.com/coil-winder.html
Check out my latest project: https://youtu.be/yXQnydST9fw
In this video I build a coil winder for winding the coils for the axial flux stators in the Reaper turbine. This coil winder includes features that eliminate some of the frustration that’s often involved with winding your own DIY coils by hand. Using a drill to drive the winder offers the ‘hands-free’ ability to lock the winder in a particular position during operation, if ever needed (most modern drills won’t turn in reverse if they’re switched to turn in the forward position and vice versa, which is what you’ll want for this project - check you drill to be sure).
The wire lock located between the two guide pulleys allows the user to lock the wire(s) in place to keep it from unraveling back onto the spool when cut. The wire lock can also be used to add a bit more drag on the wire to keep it tight and help control the drill speed too if necessary.
The spring loaded spool supports lightly squeeze the spools within the frame to keep them from spinning out of control, while the upper spring loaded pulley shaft helps to keep the wire tight as it’s being cut. With this jig properly tuned, all you need to do is guide the wire and pull the trigger.
Download the plans:
https://renewablesystemstechnology.com/coil-winder
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☀️ DIY Solar Heat Pump - Build A Solar Heat Pump System - Off Grid Living!
DIY Solar Heat Pump - Build A Solar Heat Pump System - Get the plans: https://renewablesystemstechnology.com/solar-heat-pump-system.html
In this video I show how I built a cogenerative solar heat pump system for my home, as well as how I made the diy solar panels for the array that contribute to keeping my off grid battery bank topped up. This system is perfect for off grid living because using solar and heat pump technology together increases the efficiency of each, as well as the return. Avoid wasting energy and maximize savings from your solar PV and mini-split heat pump investments by incorporating them together into one hybrid system! The heat pump pulls heat from the solar panels to keep them cool and operating at their best while increasing the input air temp into the heat pump coil to make it operate more efficiently for winter heating, as well. You can also get creative with keeping it cool in the summer by circulating pool water over the panels to keep them cool and warm up your pool while the heat pump pulls cooler air from another source to provide cooling in your home (in my case, the automatic dampers close off the airflow through the array and pull it from under my home instead). Click to learn more: https://www.resystech.com/solar-heat-pump-system1.html
Website: https://www.resystech.com
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Build A Solar Tracking System - DIY Solar Tracker - Off Grid Living!
Build A Solar Tracking System - DIY Solar Tracker - Off Grid Living! Get the plans and step by step build guide: https://renewablesystemstechnology.com/solar-tracking-system.html
In this video I build a solar tracking system for my off grid home. These trackers are relatively small compared to most, as I already have most of my solar PV on a ground rack and was limited in space on the patio. But I wanted to add a few more diy solar panels to the system and try out the diy solar tracking kits that I found on Ebay at the same time. They worked out great. The tracker structure is easy to build with treated lumber, though if you can afford it I recommend using a stainless steel pipe for the column, as this will last a lot longer embedded in the concrete. The tracking system itself (ir sensor and controller) was easy to install and set up. The actuators can be controlled manually or by the sensor, which is essentially just two tiny angled solar cells under a clear plastic dome that track the intensity of the sun.
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Build A DIY Styrofoam Mulcher
Get the plans for this project here: https://www.renewablesystemstechnology.com/foam-processormulcher.html
Check out my latest project: https://youtu.be/yXQnydST9fw
No one likes to throw money away. As builders, we’re always looking for ways to limit material waste and project costs. The processor detailed in this build guide is designed specifically for mulching scrap foam insulation board of all types, from expanded polystyrene to foil backed polyisocyanurate, but can also mulch scrap foam packaging if it is pre-cut to fit in the processor. The end product, which is basically small ¼-½” foam ‘chips’, can be easily bagged and stored for later use such as for loose fill insulation where applicable, or with the right equipment it can be further processed into plastic materials. For a builder, this processor opens a new door for efficiently turning waste into a usable product while reducing debris disposal costs as well as their ecological footprint.
Don't like ads? Neither do I. I hate them. That's why I signed up for a premium Youtube account for $12/month so that I never have to see another ad on this site again, and feel good knowing that I'm contributing to the creators I like so that they keep posting more great content. I highly recommend it. If you're just here to watch my videos, that's cool too. You can help support me specifically by signing up for a channel membership instead. Then just keep an eye on the community tab to watch these videos free of advertisements. You'll also get other perks, too. Check out the links below if you're interested.
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Build A Solar Panel Laminator
Get the plans for this project here: https://renewablesystemstechnology.com/solar-panel-laminator.html
Check out my latest project: https://youtu.be/yXQnydST9fw
With this laminator you can say goodbye to trapped air bubbles in your DIY solar panels. This DIY laminator will produce an encapsulation that is indistinguishable from a professional job and give you a peace of mind in knowing that it will last just as long as anything on the market. A complete build guide and 3D CAD for this project are available at the link below:
Download the plans:
https://renewablesystemstechnology.com/solar-panel-laminator
Don't like ads? Neither do I. I hate them. That's why I signed up for a premium Youtube account for $12/month so that I never have to see another ad on this site again, and feel good knowing that I'm contributing to the creators I like so that they keep posting more great content. I highly recommend it. If you're just here to watch my videos, that's cool too. You can help support me specifically by signing up for a channel membership instead. Then just keep an eye on the community tab to watch these videos free of advertisements. You'll also get other perks, too. Check out the links below if you're interested.
Youtube premium account:
https://www.youtube.com/premium?ybp=Sg0IBhIJdW5saW1pdGVk
Support RST specifically:
http://www.patreon.com/resystech
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DIY Axial Flux Wind Turbine: New Blades = More Power!
Get the plans here: https://renewablesystemstechnology.com/1-kw-axial-flux-hawt.html
Hit a new peak output with the new cedar blades. I wasn't expecting much of a change in power with these new blades - they're almost identical to the previous set except they have a bit more surface area in the root section to help with startup torque and are 2" longer, but I'll take more power - no complaints here lol! I'll be doing some upgrades to this turbine once I can get access to the rest of the tower sections that are currently buried under 3 feet of snow; specifically raising the tower another 16 ft higher (minimum), and making an entirely new rotor with 5 ft blades instead of 4 ft. They will also have an extremely large root section that will wrap around the nose cone to take better advantage of that area. If you look carefully, you'll notice that the widest part of the (current) blades is close to 12" away from the centre of the rotor - if that root was carried on over to the nose cone then I think I can reach startup speeds as low as 1-2 mph. Some would argue that the benefit isn't much because the cut-in speed is still higher, but the faster the rotor can build up momentum from a dead stop, the faster it will reach cut-in speed - it's a matter of saving time, not increasing power. The current blades also have a tip speed ratio of 6 (to 1). The next set of 5 ft blades will be designed with a TSR of 7. With the higher TSR coupled with the larger swept area and higher tower, these factors in particular WILL result in quite a bit more power. The pma design itself has produced up to 1000 watts for other enthusiasts (rotor size and wind speed varied), so I expect the upgrades to enable this turbine to safely produce at least 1 kW in high wind scenarios.
Website: https://www.resystech.com
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Build A DIY Axial Flux Wind Turbine Pt 13: 866 Wp @ 29 MPH
Build A DIY Axial Flux Wind Turbine Pt 13: 866 Wp @ 29 MPH
Get the plans here: https://renewablesystemstechnology.com/1-kw-axial-flux-hawt.html
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Build A DIY Axial Flux Wind Turbine Pt 12: Classic MPPT Control
Build A DIY Axial Flux Wind Turbine Pt 12: Classic MPPT Control
Get the plans here: https://renewablesystemstechnology.com/1-kw-axial-flux-hawt.html
Finally have the turbine hooked up to the Midnite Solar Classic 200. This controller almost tripled the peak output from this turbine, I'm really enjoying it. In the video I give a quick preview of my new control cabinet where all of the input power from the turbine and solar arrays is centralized and dumped into the battery bank. In the Classic I'm using Chris Olsen's power curve for his 24V DWP320 turbine. It seems to be working just fine, but I'll likely create my own curve specifically for this turbine later in the future. I have a resistor bank on the way to serve as the dump load, and a new controller/data logger for the PV/T system. After all of the components are installed I'll do a complete, detailed overview of the entire system. A step by step build guide for this project with detailed plans and 3D CADs are available at the link below:
https://www.resystech.com/axial-flux-hawt.html
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Build A DIY Aluminum Solar Heater: Bending The Trim
This video shows how to bend the aluminum trim for the DIY solar space heater.
Website: https://www.resystech.com
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Build A DIY Axial Flux Wind Turbine Pt 11: High Wind Tail Furling
Build A DIY Axial Flux Wind Turbine Pt 11: High Wind Tail Furling
Showing the wind turbine furling in high wind to help control rotor speed.
Get the plans here: https://renewablesystemstechnology.com/1-kw-axial-flux-hawt.html
Website: https://www.resystech.com
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