How to Make Wind Turbine: Tutorial with Pics and Videos

by New Physicist on

Hey, New physicist here. I am very happy to inform you that the video I published (How to make wind Turbine) nearly two months ago on YouTube got more than 1 million views till now. Thank you for your like comments and unconditional support. Many of my YouTube friends informed me that the video is very helpful to those you are planning to build a large homemade wind turbine. They also told me that it would be great if it had a voice explanation along with the video. Yeah, you can watch that video below.

Make Wind Turbine

Well, so in this blogpost, I am going to explain, how I made a real wind turbine. A wind turbine has four parts. First, the propeller, which converts the wind into energy to rotational energy. Gear and dynamo assembly is used to convert the rotational energy of the propeller into useful electric power. The tail is a part of the yaw mechanism which helps the wind turbine to face the wind, even if wind direction changes. Turbine base or tower holds all other three components at a height where the consistent wind is available.

DIY wind turbine instructions

1. DIY wind turbine Propeller

So, let’s get started.

First of all, buy a piece of PVC pipe having 60 cm in length, 6 inches in diameter, and 4 mm thickness. We have to cut 3 pieces of blades from this PVC pipe. Cut it into the required shape and make two holes to fix the blades on propeller hub. You should be very careful while handling an angle grinder. Always use an angle grinder with a guard on it and don’t forget to wear eye protection glasses.

In the next step, you need to have a little welding skill. Take a six mm nut and weld it at the center of a GI Plate washer having a 2-inch diameter.

Then weld three GI L Clamps at 120-degree distance from each other.

Always use a welding shield and glass while practicing welding. Because you need healthy eyes to watch my videos.

Yeah, now is the time to screw all three blades on the propeller hub.

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. DIY wind Turbine base

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

Next, take two ball bearings, two inch in diameter and fix it at the two ends of a small piece of GI Pipe. I Used M seal to fix them.

The next step is very important because it plays an important role in yaw mechanism, which helps the propeller to rotate itself to face the wind and maximize wind energy harvesting.

Take a Johnson wheel and remove the plastic part. Then weld the bearing part at the end of a GI pipe. Weld a piece of iron having L shape and a hose clip like this. I did all this to fix Gears, chain, dynamo and the tail on the tower.

The tail will help the propeller to face the wind. As a result, we will get the 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
    1. Weld it to one side of a 1″ square GI Pipe (1.5m)
    1. Connect bearings in a Piece of GI pipe and Place it on the johnson wheel.
  1. Weld a hose clip on it to fix dynamo.

3. DIY Wind Turbine Tail

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

    1. Screw it on a GI Piece

    1. 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 it well in the video.

Yesterday I went to a cycle workshop and asked them for an old cycle dynamo. New dynamos are not as efficient as the 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

You will get a gear, chain, and freewheel from an old cycle. Let’s assemble all the components on the base. Fix freewheel on the dynamo. I used a low-cost 12v dynamo. If you want higher output you can buy an efficient dynamo from Amazon.

Yeah, that’s it. Our horizontal axis wind turbine is ready. Now is the time to test it. Place the turbine outdoor or in front of a wall fan. Yeah, it works. You can use this wind turbine to recharge batteries, smartphone, etc. If you enjoyed this video don’t forget to click like, share and subscribe to this channel. Thanks for watching, see you soon with another renewable energy project video. Till then bye.

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, DIY wind turbine Project is ready

Watch How to DIY Wind Turbine Video

Written by: New Physicist

Aromal Karuvath (New Physicist) is a Renewable energy enthusiast, DIY project maker, Traveller, Crazy Reader, Thinker.. Love to wander around the world.. He has a Dream "100% renewably powered planet Earth.


Asif rajput

Sir I want ask one think in this project u not mention the bearing number means it's size and u assemble the bearing in some circular metal pipe it's dia how much please sir u tell me I gald to u thanks.


Yeah it's me again. Not to be rude, but your project instructions are sloppy. You don't even had the measurements for the propeller, you don't tell us how many of the nuts we need, etc. Please fix it, and it will help A LOT.


Also can you try putting your materials in a list? It's a little hard to figure out what you used. I'm trying to do this for science fair. Sorry to bug you.l


Yeah can you specify on exact measurements. Like when you say,"Aluminum sheet" how big does it need to be??? Just clarify things up a bit

Aromal Karuvath

It depends on the dynamo you use. This turbine has a potential to make an average of 6-10w. Thanks for comment. Let me know once you complete your project. Regards.


Sir i can't how much volt it gave. What's the maximum and the average volts it can give?

Aromal Karuvath

I am very happy to hear that. Do you have any video or image link? Please Provide. By the way, I appreciate your Interest in Renewable energy.


Please what is your WhatsApp number, I have make one but little different and more powerful


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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