This is a 4-foot diameter axial flux windmill, essentially a permanent magnet generator built from scratch using Hugh Piggott's design. The blades were carved out of western cedar using a drawknife and block plane, a trailer wheel hub is utilized for the alternator frame, the six stator coils were wound using #22 AWG magnet wire (301 turns per coil - which is appropriate for a 48V system) and arranged in a plywood mould with fiberglass resin poured around them to fabricate the stator. Eight NdFeB Grade N42 magnets were placed to line up with the stator coils on the outside of a steel disk with holes concentric to the wheel hub. Fiberglass resin was likewise poured into a plywood mould with the steel disk to fabricate the magnet rotor. The max power one can expect from this size windmill is roughly 200 Watts in 15 mph wind.
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