Author Topic: Carving 2*6 blades (Yes I used the search function!)  (Read 4466 times)

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XeonPony

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Carving 2*6 blades (Yes I used the search function!)
« on: May 30, 2017, 11:18:39 AM »
Now I have experience carving, I have chissles draw knifes hand planers and the luxury of a 12v skill saw.

I was going to use the 222 style blade, but I am having a very hard time conceptualizing how to set up the stations!

I need some hand holding here, Some pictures of a set up for cutting in the stations or some web pages that walk you through it or even here?

I got lots of results but most of them where threads with out much detail on the very start of the carving process, such as cutting the root and then cutting the notches for the curves and such.

Once the Woods been cut and sanded I was going to do a fiber glass resin coat on it with brass strip for the leading edge. 6 foot diameter (3foot per blade) to start.

Many thanks in advance
Ignorance is not bliss, You may not know there is a semie behind you but you'll still be a hood ornimant!

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Fused

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Re: Carving 2*6 blades (Yes I used the search function!)
« Reply #1 on: May 30, 2017, 12:11:21 PM »
I have made many sets of blades.
If a plan gives you 6 stations, then take length of blade and divide it into 6 equal
portions. At each station I mark with pencil where the plan says.
Then I take a straight edge and line up all my marks on trailing edge.
I cut down to just above the line every inch or less and break out wood sections.
Do not cut into the leading edge, just get it close to the leading edge for sanding to the edge later.
After that I form the back side with a belt sander to rough it out.
When blades are almost finished I weigh total weight of each blade.
Then I set root of blade on a block and weigh tip weight.
I sand and remove wood to get all 3 blades matching.
After mounting blades I look for tip run out, and adjust as necessary.
You also need all 3 blades equally spaced apart at tips.
Not sure it will help, but that is how I build them from a 2x6 board.
I only use boards with grain running almost vertical at end of board.
Doug

Do not mistake me for many of the more experienced contributors
on this forum. I share what I have learned only by doing it.
 
« Last Edit: May 30, 2017, 01:05:03 PM by Fused »
System specs: 480 watts peak solar, 8- 6v duracell batteries at 24v controlled with tristar 45,, wind generator is axial flux
with 5 foot blades

if good guys don't carry guns, only the bad guys will.

XeonPony

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Re: Carving 2*6 blades (Yes I used the search function!)
« Reply #2 on: May 30, 2017, 03:10:51 PM »
I appreciate the text, but the thing is I know what I need to do but I just can't convert it to a mental image it is frustrating, I wish some one where close because if I just saw it don I'd be set!

Will try it with the images I been able to see but just need a well sequenced pictures of it being don, just can't seem to find a thread with that in it.

Next I'll try hitting my head against a brick wall and see if I can jar some imagination loos!
Ignorance is not bliss, You may not know there is a semie behind you but you'll still be a hood ornimant!

Nothing fails like prayer, Two hands clasped in work will achieve more in a minute then a billion will in a melenia in prayer. In other words go out and do some real good by helping!

kitestrings

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Re: Carving 2*6 blades (Yes I used the search function!)
« Reply #3 on: May 30, 2017, 03:59:40 PM »
I can relate.  Maybe something of help here:

http://www.scoraigwind.com/selfblade/
http://otherpower.com/bladecarving.html

http://www.alton-moore.net/wind_calculations.html
http://www.warlock.com.au/bladecalc-abstract.htm

There was a fellow who posted a picture/process that I thought was called "Blade Carving 101", maybe someone else recalls.  I can't seem to find it (with my car keys).

~ks

kitestrings

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Fused

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Re: Carving 2*6 blades (Yes I used the search function!)
« Reply #5 on: May 30, 2017, 04:36:14 PM »
here are 2 sets I had made

IMG_0752 by Doug B, on Flickr

IMG_0749 by Doug B, on Flickr

IMG_0746 by Doug B, on Flickr

hope it helps visualize
Doug
System specs: 480 watts peak solar, 8- 6v duracell batteries at 24v controlled with tristar 45,, wind generator is axial flux
with 5 foot blades

if good guys don't carry guns, only the bad guys will.

SparWeb

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Re: Carving 2*6 blades (Yes I used the search function!)
« Reply #6 on: May 30, 2017, 11:34:17 PM »
www.sparweb.ca
I've written about the process too:



Hope it helps!
No one believes the theory except the one who developed it. Everyone believes the experiment except the one who ran it.
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frackers

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Re: Carving 2*6 blades (Yes I used the search function!)
« Reply #7 on: May 31, 2017, 12:13:45 AM »
I've documented my blade rebuild here http://gilks.ath.cx/gallery3/windy starting at picture 4 onwards (the first 3 pictures are why I made more blades!!).
Robin Down Under (Or Are You Up Over)

kitestrings

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Re: Carving 2*6 blades (Yes I used the search function!)
« Reply #8 on: May 31, 2017, 08:42:54 AM »
Doug,

Your blades look good, and perhaps these pics were before final sanding, but the trailing edges looks pretty thick.  This can make for excess noise.  Unfortunately, I know this from experience.

XPony,

Here are a few more photos:






I'd also make a plug for a seldom mentioned favorite tool of mine.  The "slick" (third photo) is a long-handled chisel used historically in timber framing.  Unlike a chisel you don't pound it, but rather pare with it with great control.  The angle of the blade is much shallower, and if sharpened properly will be a coveted tool in your stash.

Good luck.  ~ks
« Last Edit: May 31, 2017, 08:48:50 AM by kitestrings »

Fused

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Re: Carving 2*6 blades (Yes I used the search function!)
« Reply #9 on: May 31, 2017, 10:57:07 AM »
Thanks Kitestrings, those were only roughed out when I took that picture
Final sanding was done on back side, then I used epoxy resin to soak into
wood then light sanded again and painted.
You should have heard my garbogen howl when it got up into charging
range. I couldn't hear the blades standing at tower base but the garbogen
sure did make a noise that could be heard from the house..
I might fly it again just for fun.
I don't need major amps, just a charge on cloudy days will give
me what I need.

Doug
System specs: 480 watts peak solar, 8- 6v duracell batteries at 24v controlled with tristar 45,, wind generator is axial flux
with 5 foot blades

if good guys don't carry guns, only the bad guys will.

bcalmed

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Re: Carving 2*6 blades (Yes I used the search function!)
« Reply #10 on: May 31, 2017, 01:33:16 PM »

hiker

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Re: Carving 2*6 blades (Yes I used the search function!)
« Reply #11 on: May 31, 2017, 02:14:09 PM »
https://m.youtube.com/watch?v=1JOOGBqNd4c.   Old saw blade mill I built a few years back...the hub has the angle for the blades..just had to carve out a airfoil on back side of blades...flatten out the angle towards the tips...still take it out and fly it..motor home mill..
WILD in ALASKA

XeonPony

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Re: Carving 2*6 blades (Yes I used the search function!)
« Reply #12 on: May 31, 2017, 10:50:54 PM »
Ok slowly starting to grasp it. Thank you for all the help!, the ge222 helped, the whole twist thing for the hughs blades is still breaking the brain!

So I have a 2*6 that's say 5 feet long, I know I need a root, so measure 3 inches, but how does the rest go for figuring out stations and such.

I forsee lots of reading to come!

Short term goal is to make a set of blades for my old Air X 402 marine unit (While I had it down my pups decided that the blades where the perfect thing for teething!!!!!!!! (Lucky they are cute!)

Long term I want to make a 10 foot diameter unit

I get that I'll need to find cut in speed and all that for the air X to make proper blades.
Ignorance is not bliss, You may not know there is a semie behind you but you'll still be a hood ornimant!

Nothing fails like prayer, Two hands clasped in work will achieve more in a minute then a billion will in a melenia in prayer. In other words go out and do some real good by helping!

bcalmed

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Re: Carving 2*6 blades (Yes I used the search function!)
« Reply #13 on: June 01, 2017, 10:59:41 AM »
One good thing about the GOE222 profile is that all the "stations" are the same - there's NO taper and NO twist.....

Fused

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Re: Carving 2*6 blades (Yes I used the search function!)
« Reply #14 on: June 01, 2017, 11:27:11 AM »

I got my old blades and hub down from my barn loft.
The epoxy resin and paint has cracks here and there.
So, Im in your boat making blades too.
I'm just going to build a no twist no taper
7 degree pitch blades so it will be super quick to make.
Rough cut 1x6 cedar is my first choice.
It will be interesting watching you build that profile.
Get me a bowl of popcorn........carry on.

Doug
System specs: 480 watts peak solar, 8- 6v duracell batteries at 24v controlled with tristar 45,, wind generator is axial flux
with 5 foot blades

if good guys don't carry guns, only the bad guys will.