I started the machining on the hub today. It is solid steel about 1.5" in diameter (I didn't really measure it, I just used something I found and cleaned it up). I machined the center out for the motor shaft. That was a pain but I got it done and it looks to spin pretty true. The clearence is quite tight so there is a nice friction fit between the motor shaft and the "hub".

I figure this will all just be an experiment, so for now this is the plan for the blades: I am going to stick with the 8' because I have some foam already a nice 4' wide. There will be a hardwood spar at the thickest part of the airfoil all the way through, then fiberglass on the outside. The hub will be the thing I machined today plus "spokes" welded in for 3 blades. All 3 spokes will be connected with a ring or straight rod at about a 6" radius to tie them all together. I want to be able to adjust the pitch of the prop in my experimentation so I am going to make a rotatable connection between each blade and the hub (with, of course, a locking mechanism so the blades don't go anywhere hehehe). I haven't quite figured that one out yet. I have a few options in my head, though.

I know wood would be "better", but this is my first turbine and I am playing around with the design. Since I have the foam insulation I am going to stick to that. Plus it is MUCH lighter hehe. From what has been said I think I will be OK with direct drive. If I can't get my ~12v+ out of it then I might work on a step drive, the gearing will depend on what my results are with the direct drive. I hope direct works, though - more time for my other class project :)