"How heavy do you estimate the completed mill to be  less blades ? "

I expect upwards of 200 pounds - just guessing.  heavy - well have to hoist it, or assemble it on the tower top.

"What will you use for the yaw bearing ? Mine is pipe over pipe with grease fittings and a  1/2 thick steel washer / welded on top as the bushing, the inner pipe is thick walled with very little slop and the unit is very nearly balanced and so far it is very smooth operating. "

Ill probably use a thrust bearing of some kind.  The steel washer like you've done would probably work OK too.  On matts we put in a throwout bearing from a clutch - that worked nicely.  I'll probalby look for something like that.

"I am using a rear tapered wheel bearing hub from a mini van that is plenty heavy enough for my 12' rotor but it is really hard starting in cold weather with regular wheel bearing grease, are you using different lubricant ?"

Ive heard complaints of that before - I've never noticed any problem with it personally.  I wonder if part of the problem is the fact that you have a single rotor machine, the bearing is allready under a fair load from the magnets attracting the stator.  You probably have some (though it may be minor) drag due to iron losses as well.  Just a little bit of drag like that will make it much slower to start - even if it does turn in a light wind, it will take much more time to come up to speed.  I question if it's the grease though - I've not noticed any affect from that in cold weather.

 "Also, what do you use if anything to help keep the blades from icing up ? Sorry for all the questions but you have extreme conditions there (as do we here in Western NY) and when this goes way up later this Spring it's going to be a little tougher to mess with than 10' off the ground as is now. "

well... it's not that big!  Not compared to a few other projects that have been popping up around here lately.

"Since your getting into such a large size are you using your standard type magnets and coil sizes? Not wire size or number of turns but diameter or heigth/width sizes."

yes...
Im using a more standard shape here simply because rectangular magnets are less than half the cost of 'wedge' shaped magnets it seems.

"Are you planing to cast the stator solid as normal."

Yes - I considered making it in two pieces, so I wouldn't ever need to jack the rotors apart, but I've decided to make it solid.  It should be a bit more rigid than past once since it will be 5/8" thick.

"I am thinking since noramally the dual rotor systems I seen the stator has to be mounted from outside the diameter of the rotor, then if you leave the inner 10" or so void you save alot of resins and some weight. Not needed to fill that unless it adds strength."

Well - in this case my magnets are 3" tall, so the ID of the magnet rotor (the actual part with magnets on it) is 10".  The ID of the insides of the coils will be about 7" I figure.  So there's not much room to save here, as usual - the coils will barely clear the studs that hold it all together.

A"lso if your gennie is basically just using the outer 3" of that 16" diameter, could you build a second gennie using the inner 12" diameter that would basically be unused, sorta 2 gennies in one."

My rotors are 16" diameter, the magnets are 3" tall - so the ID is 10" - not 12".  The ID of the coil ring will be more like 7".  No room for anything like that...

 "Perhaps skew the inner gennie just a bit to offset the cogging."