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http://www.instructables.com/id/Introduction-25/
http://www.instructables.com/id/Introduction-25/
http://www.instructables.com/id/Introduction-25/
Step 4: Axle.
Take your 12mm diameter aluminium shaft and cut it to a length of 410mm. Next use a lathe to mill each end to form the step down to 9mm on each side, 30mm long on one side and 10mm long on the other. Drill a 4.1mm hole in the 30mm long end. If you have a press available use it to press-fit a 4mm diameter 30mm long steel rod 15mm deep into the drilled hole on the aluminium.
Step 5: Gearing.
We originally planned on using a standard gear pack (that you can buy at any DIY store) but when testing, we discovered that the maximum ratio we could produce using these gears did not give us the power we were hoping to achieve. To solve this problem we designed a gear on illustrator that would work with the rest of the pack we were using but would give us a bigger ratio. We laser cut this part from 5mm thick acrylic plastic. The standard gears are in red and our laser cut gear is in white. After getting the white gear laser cut we drilled a hole through it and glued one of the small gears in from the standard pack so we would have a method of fastening it to the axle. Attach the smaller gear to the motor.
http://www.instructables.com/id/Introduction-25/
Step 7: Assembly.
1. Supporting one of your turbine blades in a vice, align your support disk and hammer a pin halfway into the thickest, dowel (make sure the 'tip' of the triangle points towards the centre of the circle). At this point you should have all 5 blades attached to the support disk. At this point you can slide your smaller diameter dowel pieces into the gap between the 2 plastic sheets on each blade and nail it to the point you made earlier on your 5 pointed star. Do this to all the blades. Once all your dowel has been attached, slide your axle into the hole you've drilled though the support disk. Once done, slide the second support disk down the axle, align everything and nail the second support disk into place. This part is fairly difficult so it helps to have a vice or someone to hold it steady. 2. You should now have an almost 'bird-cage' like contraption, with all the blades pointing inwards. Slide the turbine with axle into the support brackets on the turbine stand. 3. Make a base out of a solid piece of MDF. Nail your two turbine stands to this base making sure they are very secure (this part is important because the turbine can generate enough lift at full speed to lift the front up slightly). 4. At this point you should have your actual turbine assembled and connected to your base. 5. Attach the biggest gear to the protruding piece of axle and use grub screws to secure it in place.
http://www.instructables.com/id/Introduction-25/
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http://www.instructables.com/id/Introduction-25/