Power4Home Wind Generator Guide v2

Table Of Contents
Page
3
4
6
Copyright
Legal Disclaimer
Safety Information
Section 1: Overview
Introduction
How Wind Generators Work
Advantages & Disadvantages Of Wind Energy
The Power4Home Wind Unit
Section 2: Constructing the Power4Home Wind Generator
Introduction
Materials And Tools
STEP 1: Building The Motor Housing
STEP 2: Attaching The Blade Hub
STEP 3: Building The Tower
STEP 4: Attaching Motor To The Tower
STEP 5: Building And Installing The Tail
STEP 6: Building Connecting The Blades
11
12
16
19
24
27
28
29
33
45
52
60
64
71
78
80
Section 3: Maintenance
Simple Maintenance Steps
2
Power4Home.com All Rights Reserved.
Updated: December 2009
Copyright
Copyright 2009 Power4Home.com. All rights reserved.
All literary work contained within this book belongs to and is the sole property of
its respective authors. Reproduction, copy, or any other form of use of the pieces
contained within the book is strictly forbidden without express permission from
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extent of the law.
Note: The owner of this book is permitted to print one hardcopy of this eBook for
personal use. These rules have been established to protect the rights and
ownership of the authors and to ensure that their work is upheld as their own.
NOTICE: This is NOT a Free Book. You do NOT have resell rights for this
book. I invested years of research into the creation of this resource. If you
purchased this book from anywhere other than www.Power4Home.com,
including eBay, please report that site to: support@Power4Home.com.
Thank you.
3
Legal Disclaimer
By reading and using the Power4Home guide, or the Power4Home.com website,
you agree to all terms of engagement, thus assuming complete responsibility for
your own actions. The creators, developers, publishers, and sellers will not be
held liable, nor will they claim accountability for any personal damages, loss or
injuries. You view and interact with these resources at your own risk.
All products from Power4Home.com, its related brands, and affiliated companies
are strictly for informational purposes only. While all attempts have been made to
verify the accuracy of all information provided on our website and within the
publications, circumstances and materials, known and unknown, existing or
otherwise, are unforeseeable to Power4Home.com , and as a result are beyond
the control of its creators, owners, employees, and shareholders. Neither the
authors nor the publishers can assume responsibility or liability for possible
inaccuracies including, but not limited to errors or omissions. Loss of property,
injury to oneself or others, and even death could occur as a direct, or indirect
consequence of the use and application of any content found herein.
Working with renewable energy sources can be dangerous. Since you are dealing
with electricity, high roof tops, towers, and numerous other unknown conditions,
seek qualified, opinions and help when necessary. The authors and publishers
assume that, while carrying out this project, you are aware of all the possible risks
associated with home improvements, renewable energy, and energy-related
projects in general.
Check with your town, city, state, province, county or country for applicable laws,
and/or bylaws regarding home improvements and alterations as it is customary
for necessary documentation to be required for such projects in most areas, prior
to the beginning of construction. Ultimately, you are responsible for learning
4
what local government permits and licenses are usually necessary to prevent legal
implications in your area.
The information provided may need to be downloaded using third-party software

(such as Acrobat or Flash Player) and it is the users responsibility to install the
software necessary to view such information. Any downloads, whether purchased
or given for free from our website, related websites, or hosting systems, are done
at the users own risk. No warranty is given that websites are free of corrupting
computer codes, viruses or worms.
If you are a minor, you can use this service only with permission and guidance
from your parents or guardians. Children are not eligible to use our services
unsupervised. Furthermore, this website specifically denies access to any
individual covered by the Child Online Privacy Act (COPA) of 1998.
5
Safety Information
General Information
The installation of a wind generator requires a certain level of skill and should
only be performed by a qualified licensed professional.
Cautions
1. Avoid electrical hazards when installing, wiring, operating and maintaining
your wind turbine.
2. Wind turbines generate DC electricity when propelled by wind or other
sources of moving air current.
3. When installing or working with your wind turbine, restrict turbine
rotation completely to halt production of electricity.
4. It is recommended that the components for your wind turbine remain
packed in the box until time of installation.
5. Do not touch terminals while your wind turbine is exposed to wind,
moving air currents, or during installation. As an added precaution, use
properly insulated tools only.
6. Do not stand or step on your wind turbine.
7. Since sparks may be produced, do not install your wind turbine where
flammable gases or vapors are present.
6
8. Never leave your wind turbine unsupported or unsecured.

9. Work only under dry conditions, with dry tools.
10. Wind turbine installation and operation should be performed by qualified
personnel only. Children should not be allowed near your wind turbine
during installation.
11. If not otherwise specified, it is recommended that requirements of the
latest local, national or regional electric codes be followed.
12. Use the wind generator for its intended function only.
13. Do not artificially concentrate wind or compressed air on your wind
turbine.
Warning
1. All instructions should be read and understood before attempting to
install, wire, operate and maintain your wind turbine. Contact with
electrically active parts of the generator such as terminals can result in
burns, sparks, and lethal shock whether the turbine is connected or
disconnected.
2. Wind turbines produce electricity when they are propelled by wind, or
other sources of moving air current. The voltage from a single turbine is
not considered a shock hazard. When turbines are connected in series,
voltages are additive. When turbines are connected in parallel, current is
7
additive. Consequently, a multi-turbine system can produce high voltages

and current which constitute an increased hazard.
Power Tool Safety

Power tools make work faster and let you complete projects much easier. With
that convenience, however, comes many safety concerns. Blades rotating at very
high speeds, the presence of electricity and the sheer power of some of these
tools make them very dangerous. Special care should be taken when operating
power tools.
Safety Apparel
Safety goggles or a safety mask should be worn while operating power tools.
Shards of metal or wood can dislodge at high speed and do irreparable damage to
eyes or the soft tissue of the face. Safety footwear can provide some protection
against electric shock and can also protect toes if heavy items are dropped.
Guards and Safety Switches
According to the Occupational Safety and Health Administration, guards should
be installed on power tools to protect the user from exposed moving parts. A
safety guard should never be removed while a tool is in operation.
Many kinds of saws and drills have a safety control that shuts the power off to the
tool when pressure is released. This way, if a tool is dropped during operation, it
automatically shuts off and cannot cause damage to the user or surroundings as it
falls.
Electricity
8
Power tools should be plugged into a grounded receptacle. Electric shock is a

hazard to be avoided since it can easily be fatal. Never use tools in or around
water unless they are double-insulated. Store tools in a dry place and maintain
them properly. Replace frayed or worn cords on power tools.
Pneumatic Tools
These tools are powered by compressed air and can be very dangerous without
proper caution. Before using, make sure that tools are secure on the air hose so
that they don't fly off when operating. Pay close attention when using these
powerful tools and maintain a safe distance from people who are operating them.
Eye protection is a must, and screens can also be helpful to protect bystanders or
other workers. Do not ever point a pneumatic tool at a person or animal.
Workshop Safety
Keep your work area well-lit and free of debris. Properly maintain tools and
replace worn parts. Insist that everyone who uses power tools wear safety
equipment. Do not operate power tools while distracted or under the influence of
drugs or alcohol. Respect the strength of these tools and use common sense while
working.
9
Power4Home Customer Success Story

"This is amazing! Everyone can follow these directions and if
you're like me, you'll have most of the materials needed just lying
around. Thanks again for this incredible information."
Jose C. Ford -- Bridgeport, NJ
Power4Home Customer Success Story

"The Power4Home System has saved me thousands of dollars. I've
built both the solar panels and the wind mills and they've been
running perfect for over a year. Thank you."
Matthew Bryant -- Gibsonia, PA
Power4Home Customer Testimonials

"These guides and videos are excellent, and the one question I did
have, your support team answered the same day. I'm going to
recommend Power4Home to everyone I know."
Brett Dudley -- Austin, TX

"I can't believe this worked! I've built the entire kit and now I'm
saving money on my electric bills every single month, thank you
Power4Home."
Chad Weidner -- Philadelphia, PA
10
Section 1:
Overview of Wind
Power
11
Introduction
While people have always tried to seek out new and cheap forms of energy,
recent environmental concerns along with widespread fear of a coming energy
crisis have inspired a movement towards sources of power that are also clean and
renewable.
As more and more of us get used to the idea that we cant continue to use the
same coal-burning that has worked for previous generations, we are likely to see
more and more solar panels and wind turbines dominating the skyline.
The construction of solar panels is covered in our other book on the subject, but
for the purposes of this project, we will be focusing specifically on the
construction of energy-producing wind turbines for home use. The best part is
that if you are already utilizing solar power, then wind is all you need to continue
generating free and clean power even when the sun isnt shining!
Similar to solar power, wind is created indirectly by the sun. The suns rays warm
the surface of the Earth, which warms the air above it. As the air is warmed, it
begins to move. It is this movement, this force, which we can harness and convert
into electricity just as people have applied wind power to a variety of uses
throughout history.
Wind power is not a new idea. 4,000 years ago, the Babylonians and the Chinese
were both using windmills to pump water through irrigation systems that carried
it to crops and livestock. Later European counterparts were used primarily to
grind (or mill) corn.
12
Between 1850 and 1970, approximately six million windmills were set up in the
United States alone! They were most commonly used for pumping and
distributing of water to crops and livestock.
In the late 1800s, the first windmill was adapted to produce electricity. There is
nothing very different from the small wind turbine systems that we see today
other than that they are more efficient and tend to be made from stronger,
longer-lasting materials.
So, if the technology is so old, why are we all just starting to wake up to the
benefits of wind power now?
The value of the development of modern wind turbines cannot be measured in
terms of their early successes. In fact, countless research projects on the subject
were abandoned due to a lack of funding after they failed to produce the results
that governments were looking for. Combined with plenty of political blockading
by coal-burning and hydroelectric power companies, this very effective and very
old idea has taken far too long to become available to you!
How can wind power help you?
Wind Turbines allow us to generate a steady flow of electricity from a clean,
natural and renewable source. Numerous companies have invested large sums of
money in this technology, enabling them to run entire facilities on a combination
of wind and solar power!
In the home, smaller systems can be set up to power anything including
appliances, central heat and air, pool equipment, saunas, whirlpools even high
watt machines like washers, dryers and hot water heaters. Some people have
even build large turbines (or have clustered several smaller ones) to supply their
homes with all the power they need.
13
If you are able to generate a reliable source of energy you might well decide to
disconnect your home from the power companys meter and stop paying
electricity bills forever! Modern wind turbine systems offer their owners a great
deal of flexibility in how they set up their system specifically, whether they want
the electricity to just operate certain pieces of home equipment and appliances,
or if they would prefer to have enough of a supply to power the entire home.
Its really up to you, but most people who equip their homes with a wind power
system choose to stay connected to the main power grid for a number of reason.
The power you get from your wind turbine will probably never be as reliable as
the power you are getting right now. Sorry, but unless you live in one of the few
areas where it is almost unheard of for the wind to stop blowing (Dallas, Chicago,
and Weatherford, Oklahoma to name just a few). That is just the reality of it.
Many people are waiting until commercial models become more effective, better
regulated and less expensive before they make the leap to total sustainable living.
But, it's unlikely that government subsidies or wind generator advances will
happen quickly enough to help the families who are struggling to pay their utility
bills today.
But now you know that you dont have to wait for a bunch of bureaucrats to get
around to doing something! You can build your own wind turbine power
generator for a fraction of the cost of manufactured systems!
So, you may just want to build a system that would supply electricity to all of the
large appliances in your home, and stay hooked up to the grid to use smaller
amounts of electrical power from the electric company to run things like
televisions, smaller appliances, refrigerators, lights etc. Just doing this much could
still easily cut your power bill in half!
14
Many people have realized that generating their own power not only saves them
considerable sums of money in yearly electricity bills, but that it also increases
property value!
15
How Wind Generators Work

A wind turbine or windmill is constructed with two or more blades fixed to a hub
resembling a propeller. The hub is connected by a shaft to the generator which
spins to generate electricity. These internal parts are then enclosed in a casing to
protect it from environmental elements called a "Nacelle".
16
This is a basic explanation of the operation of a wind generator. Modern

generators include additional components such as brakes and gearboxes for high
efficiency and safety reasons.
The tower holds the entire unit at least 15 feet above the ground for not only
safety but to reduce turbulence and optimize power output.
Usually, unless the wind is always blowing from one specific direction, it is
necessary for the nacelle to have a rotating mount or you wont be able to
generate much electricity once the wind changes and the turbine's blades are no
longer facing the wind at an optimum angle. In order to manage this, the rear of
the nacelle is fitted with a windmill vane which the wind forces into the direction
it is blowing, ensuring that the turbine is always facing the wind.
It is critical to your projects level of success that you mount your wind turbine as
high off the ground as is securely possible so that you are harnessing as much of
the winds force as possible. Failure to do so may result in periods of no
generation of electricity, when you might otherwise at least have some!
So, the wind turns the turbine generator, mounted in the prop area of the nacelle,
which produces electricity that travels through the stator that directs it down the
tower through wires.
How the current is handled from there is covered in our Installation Manual and
does not have to do with the function of the wind turbine itself. But looking
ahead, you may wish to know that it is possible to incorporate various
components that can register and transform the energy, both coming in and going
out, to be stored and used in different ways. But enough of that for the time
being One thing at a time!
17
How many times have you wished you could bring down your electricity bill just a
little? How many times have you wished you could stop having to rely on the
power companies with their fluctuating rates? How often do you wish that there
was a cleaner, more environmentally friendly to keep the lights on, without using
power that you know is generated by coal-burning power stations?
There is another way. And were going to show you how
18
Advantages & Disadvantages

Of Wind Energy
Lets be really honest here for a second Wind power is not for everyone. And
before you commit yourself to this project it is important that you determine
whether or not it's the right solution to your needs.
To begin with, the wind can stop blowing without notice. This is probably the
reason that most people whose properties consistently get plenty of wind remain
connected to the main power grid even though they could potentially switch
their entire home over to wind power.
If you run certain devices using your wind turbine and the wind stops blowing, the
power will go out and you'll have to wait until the wind starts blowing again.
There are ways to prevent this and the most common is to use a battery bank to
store excess power for times when the wind is not blowing.
While this may sound a tad inconvenient, consider the increasing unreliability of
conventional power in recent years: blackouts due to overloaded grids and
extreme weather have plunged huge portions of both the United States and
Canada into darkness in some areas lasting for more than a month!
Just ask any victims of Hurricane Katrina if they wish theyd had a wind turbine
handy to generate any amount of electricity to power lights or heat water during
the storms aftermath.
19
Generally, average annual wind speeds of at least nine to ten miles per hour are
required to make a small wind turbine cost-effective. A useful resource for
evaluating a site for its wind energy potential is a wind resource potential map
which can be accessed for most areas on the Internet.
When evaluating your propertys wind resources, you may want to make sure
that most of the following conditions are met before committing yourself to this
project:
Your property is at least one acre in size
Your local zoning laws allow wind turbines
You are comfortable with making long-term investments and lifestyle
changes
Your turbine can be placed far enough from your neighbor's house that
they cant hear it (decibels will vary by model and turbine size)
20
When it comes to your neighbors, please be considerate. The most vocal

opponents of wind power feel strongly about the need to preserve the
appearance of the natural landscape, and believe that wind turbines everywhere
might disrupt the peace and quiet of their neighborhoods.
Discuss your plans to utilize wind power with them, understand that people are
often suspicious of new and unknown technologies and be prepared to respond
to their concerns. If they are still opposed to your plans, you should probably not
take your wind turbine project any further unless you plan to move to a more
appropriate location for wind power: its just not worth making yourself the
source of a negative political situation in your neighborhood.
The fact is that many concerns raised about wind turbines are not true. Small
wind turbines for home use are not, as some people believe, dangerous to birds
certainly less dangerous than the glass windows used in homes, offices and
buildings everywhere!
Critics will also tell you that wind turbines have the potential to interfere with
radio and television signals. While there is some evidence of this among older
styles of turbines with steel blades when located close to the home, all modern
turbines, large and small, have blades made of fiberglass or wood and are
transparent to radio and television waves. In fact, today's small wind turbines are
often used to power mobile telecommunications for both military and
commercial uses!
Your neighbors' concerns relating to wind turbine noise are important. Even when
building small wind turbines for the home, the potential for any noise to bother
other people is always a possibility. Even though the loudest turbines you can find
do not even come close to making enough sound to violate noise bylaws, the
noise they produce may still be objectionable to other people.
21
Before setting up your wind turbine, you should be aware of sounds it could make
and what you can do to minimize them:
A characteristic whooshing noise could be made by the flow of air over
the blades of your turbine, and may increase with the speed of the
generator
Mechanical noises may also be produced by the components of a wind
turbine. Normal wear and tear, poor craftsmanship or a lack of
maintenance may all be factors contributing the amount of noise produced
The environmental advantages of using wind turbines to tap into the wind as an
energy source should be fairly obvious. Wind energy is non-polluting and reduces
the demand for higher-impact electricity from thermal stations (e.g. oil, natural
gas and coal), hydroelectric dams and nuclear power stations. Additionally:
Wind is a free and readily available resource
Turbines require no fuel or additional energy sources to run
Turbines produce no waste or greenhouse gases
Turbines are a great way to supply energy to remote areas that cant be
connected to the main power grid, or routinely suffer power outages
Since restrictions governing wind power have recently been relaxed specifically
in regards to the size and height of turbines that may be used in a given area
there is nothing to stop you from using this technology to save thousands of
dollars in long-term energy costs.
The best part is that you can do this today, without waiting for the government or
big corporations to take the lead by integrating wind farms into our power grids in
order to solve our energy needs, and help the environment. It's certainly not in
their best financial interests for us to make our own power at home. But there is
22
nothing stopping each and every one of us from taking a 4,000 year old idea and
using it to save power and money while saving the planet at the same time!
23
The Power4Home Wind Unit

At Power4Home.com, our aim is simple: To provide you with the most current
research and up to date knowledge on practical do-it-yourself wind power
systems, so that you can build our tested wind turbine project safely with
confidence and ease. Either as a stand-alone solution to your home energy needs,
or used in conjunction with Power4Home.coms solar power units, our wind
turbine system will allow you to break free from the power companys control
over your energy costs and do something positive to help the environment in the
process.
Not only will our tested system help you save electricity costs, but the start-up
cost of our system is as little as a tenth of the initial expense of setting up most
commercial wind turbine models!
Our systems are designed with long-term savings in mind, so it would be foolish of
us to develop an inferior product that wasnt going to continuing to work for you
decades down the road! Our wind turbine design is very durable: existing models
have been running for years without maintenance of any kind and are still running
strong!
You will not encounter any of the usual complaints people have with either homemade or manufactured systems Our wind turbine is designed to run optimally at
both high and low wind speeds.
24
We are certain that you will be very proud of your wind turbine! Not only is the
construction process easy, but it is also intended to be enjoyable, providing you
with an inside-out and hands-on understanding of how your unit functions.
Attitudes towards alternative power sources have been shifting for some time,
yet the small wind power generator for the home is still an uncommon sight. Do
not expect this to be the case for long. I applaud you for choosing to be one of the
first in your community to choose cleaner energy solutions for the future!
Most of our customers also agree that the Power4Home.com wind turbine design
looks really cool and should disprove any old-fashioned notions that some
people have about the unattractiveness of these devices.
Furthermore, our wind turbine can be built using very common, inexpensive and
easy to find parts, so you dont need to worry that you wont be able to get your
project off the ground.
Additionally, several mounting options are available within our plans, so it is up to
you how you set up your wind turbine.
Our customers have indicated that it is important to them that our plans be
customizable, so that they can experiment with different materials, test the
performance of different set-ups, and direct and store the energy produced in a
variety of ways to suit their needs. As we have continued to develop this product,
we have incorporated this level of flexibility along with a knowledgeable service
team who is quick to respond to any problems or questions you might have.
With Power4Home.coms wind turbine you are not bound by the availability of
parts or limitations of a boxed system! By providing you with everything you need
to know, and everything you need to have in order to build a high-performance
25
wind turbine, we have given you the freedom to adapt our methods to your
specific situation.
In the next section I'll explaining now to actually build the Power4Home Wind
Generator step by step.
26
Section 2:
Construction of The
Power4Home Wind
Power Generator
27
Introduction
Today, the only reason everyone doesn't power their home with wind energy is
the initial cost of a complete system and that some areas just don't have enough
wind for it to work. Commercial wind generators range from $800-$5000 or
more. In most cases, making your own wind generator can save you several
thousands of dollars.
The Power4Home System allows you to scale to meet your needs. You can start
with one wind turbine and then add a few more to handle even the most
demanding residential needs.
If you've never built anything before don't worry. Even with no experience, most
people can build a complete Wind Generator in less than a few hours.

"At first I wasn't quite sure if I could handle this projects, I've done
a few things around the house, but nothing like this. To my
surprise, everything was straightforward and easy to understand."
Martha R. Cardwell-- Philadelphia, PA
Everything is explained step by step both in this eBook as illustrations and photos
or by watching the included videos.
28
Materials Required
Wood
Description:
3 (12 ft 2"x4")
1 (8 ft 2"x4")
1 (10 ft 2"x4")
1 (4 ft 1"x6")
ABS Pipe
Description: 36" pipe with a diameter of 1
1/2"
Generator Motor
Description: This is available at our store at
www.Power4HomeStore.com
Head Bearing
Description: Ball Bearing
29
TurnBuckle
Description: 5/16" Turnbuckle
2 Wood Loops
Description:
Bungee Cord
Description: Used to prevent electrical cord
from tangling
Cap
Description: Easily found at your local
hardware store.
Hub
Description: Easily found at your local
hardware store. Look for an exhaust fan.
30
Fixit Stick
Description: Helps with fitting of sized parts
White Out (Optional)

Description: Standard office liquid paper.
TOTAL COST:
31
Tools Needed
Power Drill
Description:
Robertson #2 bit
#2 Phillips bit
9/16" drill bit
3/32" drill bit
7/32" drill bit
1/4" drill bit
Nuts, Bolts, And Washers

Description: Found at your
local hardware store
Socket Set
Description: Standard
Hole Hog
Description: 3.5"
Wrenches
Grinder
Channel Locks
Gorilla Glue
Screws
Description: Various sizes
listed in this guide
Safety & Protective

Equipment
Description: Always wear
safety equipment.
32
STEP Building The Motor

1 Housing
Step A
Cutting The Housing Pieces
1. Hole hog a hole for the motor half an inch from one end of the one-by-six,
making sure to drill a hole at the bottom so the motor will fit.
33
2. Drill a hole at the bottom of the circle to fit the motor.
3. Cut out the remain hole.
34
4. Cut two 6 long pieces, two 7 pieces, and two 5 3/8 pieces from your oneby-six. The piece with the hole through it should be 6 inches long.
5. Begin assembling the housing. The 5 3/8 pieces make the top and the bottom,
the sides are the 7 pieces, and the front and back faces are the 6 pieces.
Make sure to drill your pilot holes using the 3/32 drill bit.
35
Step B
Attaching The Motor
1. Put whiteout around the screw holes and press it into the motor opening.
36
2. Before attaching the front piece, mount and drill the motor onto it.
37
Step C
Fin Connector & Wiring Hole
1. Mount the cap onto the back piece, then mark and drill the holes.
38
39
2. Drill a hole in the bottom piece through which the wire will run.
3. Screw in the 3 sides to the base.
40
4. Attach the bearing to the bottom of the housing. Be sure to carefully align your
drill holes so as not to interfere with the motor.
5. Mark the box to drill a hole to allow access for a drill when mounting to the
tower.
41
6. Drill the hole you just marked
TIP
We'll use this hole later to help us bolt this motor housing
to the tower.
42
43
7. Drill rivets into the hub.
44
STEP Attaching The Blade Hub

2
Step A
Remove Blades
1. Drill the rivets on each fin to remove the blades.
45
46
Step B
Connect The Hub Shaft
1. Use a drill with a 9/16" drill bit to widen the hole.
47
2. Cut the loop of the buckle.
3. Place the cut end of the turn buckle in the blade hub and tighten it into place.
Make sure to cover the end with either lock tight or gorilla glue to help hold it in
place.
48
Step C
Connect The Hub To The Motor
1. Use a 4. Mix the two compounds in the fixit stick and apply it on the threads of
the motor.
49
2. Tighten the hub to the motor.
TIP
Keep tightening until it starts getting tough, and then stop.

The pieces are made of aluminum and if you keep
tightening them you'll strip the thread.
50
3. Set the motor aside for 3 hours to let the fixit component dry.
51
STEP Building The Tower

3
Step A
Cutting Tower Pieces
1. Cut 8 tower brace supports, each 10 9/16 inches long, from the 8-foot long
two-by-four.
52
2. Cut 4 pieces to make up the tower brace, each 22 1/8 inches long, from one of
the 12-foot two-by-fours. The corners should be angled at 45 degrees, with the
measurement taken on the long side.
3. Cut 4 legs, each 22 3/16 inches long, from one of the 12-foot two-by-fours.
53
4. Cut 4 leg connectors, each 31 5/16 inches long, from the last 12-foot two-byfour. Again, the corners should be angled 45 degrees, with the measurement
taken on the long side.
Step B
Assembling The Base Of Tower
1. Attach the tower brace supports to the four-by-four, two on each face. Be sure
to alternate the screwing pattern so that each piece of wood is securely attached
to the piece below it. The braces should end the width of one two-by-four from
the bottom of the four-by-four.
54
55
2. Attach the legs.
56
57
3. Install leg connectors.
58
4. Install the tower brace supports.
59
STEP Attaching Motor To The

4 Tower
Step A
Preparing The Tower
1. Place the tower on a table or something similar to have it running horizontally.
60
2. Drill a hole through the top of the tower to the side for the power cable to run
through. Then run the cable through and get the motor assembly into position.
Tower
Step B
Angle of Hole
Mounting The Motor Assembly
1. Use the hole you drilled earlier to start putting in the screen to hold the motor
assembly to the tower. Turn the motor assembly 90 degrees and add the next
screw. Repeat until you have all 4 screws tightened.
61
TIP
Use a drill bit extension.
62
Step C
Closing The Motor Assembly
1. Install the side piece of the motor box with 9 screws.
2. Finally, install the top piece with screws.
63
STEP Building And Installing

5 The Tail
Step A
Preparing The Fins
1. Use a drill bit to drill out the existing hole.
64
2. Drill a second hole right before the divot in the fin.
3. Align the 2 fins and drill though the existing holes to make the second fin a
duplicate of the first.
65
Step B
Preparing The Tail
1. Mark the holes with whiteout to mark the holes on the plastic pipe.
66
2. Drill right through both sides of the pipe when you just marked it.
Step C
Connecting The Tail
1. Place one fin on each side making sure the fins are curving outward. Then
place a bolt through both holes and tighten with nuts.
67
2. Grind the ends of the bolts to make them flush.
68
3. File the inside and outside of the plastic pipe to provide more surface area for
the glue.
69
4. Apply a little layer of Gorilla glue to the inside of the pipe.
5. Let that dry for 3 hours.
70
STEP Building And Connecting

6 The Blades
Step A
Drill Holes In Blade
1. Mark the holes with a pencil for the Blades by aligning the hub to the center of
the blade.
71
2. Drill the holes on the first blade.
72
3. Stack the remain 2 blades and drill through the holes from the first blade you
drilled.
Step B
Cut Blades Into Shape
1. Measure and mark each blade 6 from the top by the drill holes.
73
2. Measure and mark the bottom at 2.
74
3. Draw a line connecting the two points.
4. Use a jigsaw to cut along the line you just drew.
75
5. Cut the corners of the top edge near the screw holes and remove the
protective plastic on both sides of the blade.
76
Step C
Connect Blades To Hub
1. Install each blade onto the hub. Make sure the straight edge of the blade is on
the side of the hub blade that furthest from the motor.
77
Section 3:
Maintenance
78
Wind Turbine Maintenance

Now that you've built and installed your wind turbine, there are a few things you
can do to ensure that it lasts as long as possible so that you can get the most out
of your investment.
Unlike Power4Home.coms solar panel unit which contains no moving parts and
requires almost no maintenance there are some basic steps you should be ready
to take in order to allow your wind turbine to continue to function properly and
efficiently for decades.
But don't worry, small turbines have very few moving parts and require minimal
maintenance. They are designed for a long life (up to 20 years) and are intended
to operate completely automatically.
We strongly encourage you to follow our instructions for the assembly of your
wind turbine as closely as possible.
Make sure all wood parts are thoroughly painted or varnished in order to protect
them from the elements.
After 20 years, blades and bearings may need to be completely replaced. With
proper installation and maintenance, your turbine can last 20-30 years or longer!
Proper maintenance will also minimize the amount of mechanical noise produced
by your wind turbine and in turn, any new noises your turbine begins to make
can be considered possible indicators that it may not functioning properly.
79
Simple Steps To Maintaining

Your Wind Generator
WARNING
STEP
Make sure you secure the blades so they cannot move

freely during maintenance. If you don't do this, a sudden
gust of wind can become a safety hazard.
Once every 3-6 months apply oil or grease on all moving parts.
Visually inspect the wind generator for any obvious cracks or
other physical damage.
STEP
Like any machine, you should check bolts and electrical

connections annually; tighten if necessary. Listen for unusually
sounds as they may indicated a problem with your wind
generator.
STEP
Once a year, check wind turbines for corrosion. Also check the
wiring to make sure nothing is out of place. Replace any wiring
that has become frayed, loose or otherwise compromised. Test
the output wattage of the wind generator to ensure it is working
optimally.
2
3
80

Power4Home Wind Generator Guide v2

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Table Of Contents

Updated: December 2009

Updated: December 2009

Updated: December 2009

The information provided may need to be downloaded using third-party software

Updated: December 2009

Updated: December 2009

8. Never leave your wind turbine unsupported or unsecured.

Updated: December 2009

additive. Consequently, a multi-turbine system can produce high voltages

Power Tool Safety

Updated: December 2009

Power tools should be plugged into a grounded receptacle. Electric shock is a

Updated: December 2009

Power4Home Customer Success Story

Jose C. Ford -- Bridgeport, NJ

Power4Home Customer Success Story

Matthew Bryant -- Gibsonia, PA

Power4Home Customer Testimonials

Brett Dudley -- Austin, TX

Power4Home Customer Testimonials

Chad Weidner -- Philadelphia, PA

Updated: December 2009

Updated: December 2009

Updated: December 2009

Updated: December 2009

Updated: December 2009

Updated: December 2009

How Wind Generators Work

Updated: December 2009

This is a basic explanation of the operation of a wind generator. Modern

Updated: December 2009

Updated: December 2009

Advantages & Disadvantages

Updated: December 2009

Updated: December 2009

When it comes to your neighbors, please be considerate. The most vocal

Updated: December 2009

Updated: December 2009

Updated: December 2009

The Power4Home Wind Unit

Updated: December 2009

Updated: December 2009

Updated: December 2009

Updated: December 2009

Power4Home Customer Testimonials

Martha R. Cardwell-- Philadelphia, PA

Updated: December 2009

Updated: December 2009

Updated: December 2009

White Out (Optional)

Updated: December 2009

Nuts, Bolts, And Washers

Safety & Protective

Updated: December 2009

STEP Building The Motor

Cutting The Housing Pieces

Updated: December 2009

2. Drill a hole at the bottom of the circle to fit the motor.

3. Cut out the remain hole.

Updated: December 2009

Updated: December 2009

Attaching The Motor

Updated: December 2009