Seems some guys are mixing pipe dia and blade dia.
I'm no expert.
If they are anything like the ones I played with,
The 4' of 6" blades should start easier than the 3' of 3".
I would not expect the thickness to be a very bad thing.
Even the ones I really mangled started OK.
My worst ones started to show problems at maybe 60RPMs.
The only thing I can think of is a problem with the gennie end.
Maybe the extra weight on the bearings? Or bending the shaft to bind the bearings?
Maybe a short in the gennie?
Is there a output load with the 4' that was not there with the 3', like a light bulb to act as a brake?
Maybe lay it flat, blade facing the sky and see if it spins free,
then try blade facing the ground.
Maybe take it in a quiet house and listen for grinding or other evil noises as it turns.
Let us know,
G-