How to Turn Scrap Metal into a Working Wind Turbine

Check out this amazing scrap metal and plastic working DIY wind turbine.

If the video player is not working, you can click on this alternative video link.

If you have a pile of old metal and an old printer lying around doing nothing, why not consider putting them to work? With this simple guide, you can convert them into a practical DIY wind turbine

Read on to find out how. 

diy wind turbine complete
Source: Tech Paradise/YouTube

As you can imagine, like any project of this nature, you'll need some tools and materials before you get started. 

Materials and gear needed

Step 1: Make the blades and supports

With all your gear and materials in hand, it is now time to get on with the build. First, grab your uPVC piping and cut it into 5-foot-long pieces. 

Mark out the shape of the blades and cut them out too. You can use something like an angle grinder to make short work of this. 

Advertisement
diy wind turbine make blades
Source: Tech Paradise/YouTube

With the blades ready, take your mild steel plate, and mark out a square 10-inches (25.4cm) by 10-inches (25.4cm). 

diy wind turbine steel plate
Source: Tech Paradise/YouTube

Grab your angle grinder and cut out the square. With the square removed, rub the angle grinder over the cut edges to remove any barbs and other sharp edges, as needed. 

diy wind turbine steel plate
Source: Tech Paradise/YouTube

Next, use something straight, like a metal ruler, to mark out two intersecting diagonal lines across the plate. This is to find the exact center of the steel plate. 

diy wind turbine find center
Source: Tech Paradise/YouTube

With that complete, mark out a horizontal and vertical line that also transects the center point. 

diy wind turbine hor and vert lines
Source: Tech Paradise/YouTube

With the plate ready, return to your turbine blades and, if not already in place, cut two bolt holes on the base of the leading edge of each blade. 

Take a measure of the distance between the holes. 

Advertisement
diy wind turbine blade bolt holes
Source: Tech Paradise/YouTube

Return to your steel plate and mark the position of the first bolt holes on the vertical and horizontal lines of the plate about 3/8 of an inch (10mm) from the edge. 

diy wind turbine mounting points
Source: Tech Paradise/YouTube

Punch the holes using a hammer and nail or center punch. With that complete, drill 1/8 of an inch (3mm) holes through the punch marks for the first blade mounting points. 

diy wind turbine drill holes
Source: Tech Paradise/YouTube

Also, drill a hole through the very center of the plate. Next, mark out the second bolt holes the same distance away from the first as they are on the blades. 

Punch the points once again and drill pilot holes as before. With that complete, enlarge all the holes to 15/64ths of an inch (6mm). Be sure to add some form of lubricant when doing this (coconut oil is pretty good FYI).

Advertisement
diy wind turbine clean drill holes
Source: Tech Paradise/YouTube

Once complete, clean down the steel plate and remove and barbs and other sharp bits of metal using your angle grinder. 

Step 2: Complete the main turbine support struts

Next, take the steel strips and mark out a series of lines for mounting the rotor support plates. 

diy wind turbine plate to supports
Source: Tech Paradise/YouTube

Once complete, drill a series of 5/64ths of an inch (2mm) pilot holes along the mounting points. Enlarge the holes to 15/64ths of an inch (6mm). 

diy wind turbine mounting holes struts
Source: Tech Paradise/YouTube

With that complete, cut up the metal strip into smaller strips using your angle grinder. 

diy wind turbine small lengths
Source: Tech Paradise/YouTube

Remove any barbs and sharp edges from the cut edges as before. 

Step 3: Weld the rotor supports

With the main rotor supports complete, we can now begin to build the turbine. Take the remaining long steel strip and start to spot weld the rotor supports steel to it. 

Take one of the longest smaller strips to spot weld it at 90-degrees to the very end of the main strip. Then take a long bolt and mark out the position of the second long piece of metal. 

Advertisement
diy wind turbine rotor supports weld
Source: Tech Paradise/YouTube

Ensure both pieces are perfectly square and perpendicular to the main support. Also, test that the bolt can freely move. 

Once happy, fully weld the pieces and keep checking that bolt (which will be a rotor) can fully, and freely, rotate. 

Take the smaller plates now and weld them to the other end of the same larger strip of metal. As before, ensure the plates are square and perpendicular. 

diy wind turbine smaller plates
Source: Tech Paradise/YouTube

Adjust as needed, as before, to ensure the guide bolt can freely rotate. 

Step 4: Assemble the blades and begin to complete the turbine-proper

Take your square metal plate and add an M6 blot through the central hole. Add washers, and secure the bolt into place using nuts. 

diy wind turbine assemble blades
Source: Tech Paradise/YouTube

Once complete, take some smaller 6mm bolts and nuts and affix each blade to the plate. Add each blade at 90-degrees to one another. 

Advertisement
diy turbine add blades to hub
Source: Tech Paradise/YouTube

With the blades now fully secured to the hub, take the entire assembly and mount it to the main support bar using a long bolt. 

diy wind turbine hub to main support
Source: Tech Paradise/YouTube

Add a nut to the end of the bolt to keep the hub in place, but do not tighten fully to allow it to move freely. Next, clamp the entire frame to an equally sized length of square tubular steel. 

Weld the two pieces together, as needed. 

diy wind turbine weld supports
Source: Tech Paradise/YouTube

With that complete, erect your main turbine post in place. Secure it into place as needed (whether by cementing into place) and then add your main wind turbine assembly to the top of the post. 

diy wind turbine mount turbine
Source: Tech Paradise/YouTube

With that complete, take your old plastic or metal corrugated sheet. Mark out the design and dimensions of the rear rudder for the turbine, and cut out the piece using your angle grinder. 

Advertisement

With that complete, drill mounting holes through the rudder to attach it to a support pole for later attachment to the main turbine assembly. 

diy wind turbine rudder
Source: Tech Paradise/YouTube

With that complete, take an old piece of uPVC piping, or wood, and secure it to the rudder using the mounting holes you just drilled. You can use old metal brackets, or cable ties to get the job done. 

diy wind turbine rudder support
Source: Tech Paradise/YouTube

With that complete, transfer your entire rudder assembly to the main turbine and secure it to the rear of the blade support pole. Again you can use cable ties to do this, or create a more stable method of mounting the two pieces. 

diy wind turbine attach rudder
Source: Tech Paradise/YouTube

Once complete, leave the structure to move freely and see if the blades rotate and the entire assembly moves with any changes in wind direction. If not, adjust accordingly. 

diy wind turbine test action
Source: Tech Paradise/YouTube

Step 5: Build the turbine's power generation system

With the main mechanical assembly of the wind turbine now complete, we can move on to building the electronic gubbins. Take your old printer, locate and remove the stepper motor in as complete a condition as possible. 

diy wind turbine stepper motor
Source: Tech Paradise/YouTube

Test the motion of the gears, and lubricate if needed. Next, if you want to, you can wire the motor up to a volt-meter and test that it generates power when you manually turn the gears. 

diy wind turbine test motor
Source: Tech Paradise/YouTube

Once you are happy, design and build a mounting fixture for the stepper motor to your wind turbine assembly. 

diy wind turbine stepper mount
Source: Tech Paradise/YouTube

Next, build a coupling to connect the turbine blade axle to turn the gears of the stepper motor. 

diy wind turbine coupling
Source: Tech Paradise/YouTube

In this case, the creator used a pair of bolts to build a forked assembly that will be used for this purpose. Cut off any excess bits of metal as needed. 

Once complete, couple the stepper motor to the main turbine shaft as needed. 

diy wind turbine coupling to motor
Source: Tech Paradise/YouTube

With that complete, reattach the turbine main assembly to the wind turbines mast or pole. 

diy wind turbine coupling closeup
Closeup of the coupling assembly. Source: Tech Paradise/YouTube

Once mounted, test the action of the turbine and stepper motor. As the blades turn, they should easily turn the stepper motor. 

If not, adjust the assembly as needed. Once again you can wire up the stepper motor to your voltmeter to see just how much juice your turbine puts out. 

You can also wire up some other small electronic devices like an LED emergency light. The turbine should generate enough electricity to power it!

diy wind turbine test turbine
Source: Tech Paradise/YouTube

With that, your DIY scrap wind turbine is now complete. All you need to do now is decide what you want it to power on regular basis. 

If you enjoyed this project, you may enjoy some other scrap-to-engineering-gold projects. How about, for example, a stylish outdoor hose holder?

Interesting Engineering is a participant of the Amazon Services LLC Associates Program and various other affiliate programs, and as such there might be affiliate links to the products in this article. By clicking the links and shopping at partner sites, you do not only get the materials you need but also are supporting our website.

Follow Us on

Stay on top of the latest engineering news

Just enter your email and we’ll take care of the rest:

By subscribing, you agree to our Terms of Use and Privacy Policy. You may unsubscribe at any time.