Ed,
Is there very much force on the "cups" trying to change their shape when it is running in a fair bit of wind? I'm trying to imagine some easier construction methods for something that is shaped very much like your machine.
Instead of taking the time to form the cups around the nice "spars" that you created, would it work to go back to a "top plate and bottom plate" design, and cut appropriately shaped slots in the end caps to trap a piece of sheet metal and hold it in the same shape? Just use a router to make a narrow slot in three places that is the same shape as the cross section of your "wings" or "cups" or whatever we are calling them? The sheet metal would to all the way through the disk, and then get fastened to the outside of the disk in some way
Some other contraption would be needed in the center to hold the end-caps in place and some good way to affix the sheet metal to the end caps where it passes just through them. Maybe just cut the ends of the sheet metal into tabs and fold them back down onto the disks and screw the tabs to the disks.
Does this sound at all practical? I'm sure it would work for a really short machine, but perhaps if one wanted to scale it up to 6 or eight feet long I fear there would be too much flexing of the sheet metal going on near the center. Perhaps just another disk with the same slots that slides down into a middle position and gets affixed there.
Also, if you were to scale up your design (to a larger radius), do you think you would go for three larger "wings", or do you think you would keep the wing size similar and use more wings?
BTW, using your 8 watts/sq foot number (at 20 mph?), and keeping to readily available material sizes, one could do a 4 foot radius 8 foot long machine for 256 watts. Placing these tightly along the North-South ridge of my eventual wood-shop building tightly packed, one could imagine approx. 30 ft * 8 feet * 8 watts/sqfoot = 1920 watts in a 20mph wind. Not too shaby. I know, I know, have to over build the shop buiding to handle it. Probably also have to use some of those watts to run a noise canceling sound system when I'm in there working!
thanks,
jp