How I made A Real Wind Turbine!

by Aromal Karuvath on

  1. I have been thinking to make wind turbine (a large horizontal axis one) since I first published a small wind turbine video on youtube and a blog post here a few years back. That video went viral. Then I decided to make one large functional wind turbine. The former didn’t give me even 1.5 volts. I know building a medium sized wind turbine will take a lot of time to complete. But, It didn’t, I’ve Just finished a medium sized wind turbine with only 5 days, 2 hours per day after my regular work. By the way, Here I am going to give you an overview of my experience in making this wind turbine Project.

Make Wind Turbine 

make wind Turbine

wind Turbine


I am a renewable energy passionate. I love to make renewable energy related projects and upload video to Youtube. Kindly subscribe to my channel for more Green Power projects.

Watch How to Make Wind turbine Video

1.Propeller Making

A propeller is the most important part of a wind turbine. The propeller is used to convert wind energy to rotational energy. This rotational energy can easily be converted to electricity by coupling it with a dynamo. Wind turbine blade should have appropriate curvature and weight to get maximum efficiency. So, I bought 6mm thick, 8 Inch Heavy duty PVC pipe ($5). Then I used a hand grinder to cut it into wind turbine blade shape with 1:3:20 ratio.

You can easily make rotor to connect these blades using a Plate washer, Nut, and GI L-clamps.

Take 8 inch, 4mm PVC Pipe

Cut it into blade shape 1:2:30 Ratio as shown in the figure

Smoothen the edges.

Take a 3 Inch washer and weld GI Pieces on It.

Screw PVC blades On it.

2.Turbine base Making

Another important function of a wind turbine is its ability to face the wind automatically. Otherwise, it won’t be able to maximize the wind energy harvesting. This mechanism is called yaw mechanism. It works with the help of a flexible turbine base and a tail. I used a johnson wheel to make this flexible joint.

The tail will help the propeller to face the wind. As a result, we will get maximum output. We can cut aluminum sheet very easily to any shape. Cut it to a proper shape.

  1. Take a Johnson wheel and remove the wheel
  2. Weld it to one side of a 1″ square GI Pipe (1.5m)
  3. Connect bearings in a Piece of GI pipe and Place it on the johnson wheel.
  4. Weld a hose clip on it to fix dynamo.

3. Tail Making

The tail will help the propeller to face the wind. As a result, we will get maximum output. We can cut aluminum sheet very easily to any shape. Cut it to a proper shape.

  1. Cut aluminum sheet into wind turbine tail shape

  2. Screw it on a GI Piece

  3. Fix the tail on Wind turbine Base

Safety First Approach

Keep in Mind that safety must be the first priority. If you are not familiar with angle Grinder, I strongly recommend you not to use it. In any case, children should not experiment with it.  Also, when welding you should wear eye protection glasses, face shield, and hand gloves. Ask professional welders to get your work done. That would be better. I have worked as a welder and wireman two years, so I have some experience it such things. Thank God.

Then I made a base using GI Pipe and anglers. Watch the above video for all other connection procedures. I have explained them well in the video.

Yesterday I went to a cycle workshop and asked them for an old cycle dynamo. New dynamos are not efficient as old one. Besides, cycle dynamos are AC GENERATORS. The Output will be alternating current. It is better to use a DC Dynamo instead of AC in a small scale power generation system. But I couldn’t Find one. No problem, we can use either.

4. Assemble Each Component together

Watch Video Closely to assemble each Component Together. Make sure the crank wheel and flywheel align straight. Then Connect the output to a battery or multimeter. Place the wind turbine outside where the wind blows.

That’s It, make wind turbine Project is ready

Written by: Aromal Karuvath

Hi, Making energy-related projects is my passion. I Hope you have enjoyed this project. I Need your help. You can suggest project ideas through commenting areas of any project. If it is simple and interesting we will credit you in that project guide.



Sir, could you please share the dimensions of the design of the turbine blade as I am not able to figure out that?


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