Here's the way I cut my test blade.
My "theroy" is instead of making a blade to spin faster in high winds, the blade should have some type of drag.
but.. should collect/grab a lot of wind in low wind. So instead of trying to get the blade to spin as fast as it can in all wind speeds, don't worry so much about it spining upteen hundred rpms in winds of 45mph+. Just worry about trying to keep the blade spinning strongly at 200-300 rpms in 2-5 mph winds. give the blade some drag so in high winds it maybe only spins at 600 rpms.
My personal progress to date is:
-I got 16 wedge magnets
-14ga coil. I've winded my first coil several times now, keep undoing it to see what kind of consistancy I can keep.
-no workshop, doing work in 6 X 10 area of 23 x 26 living room. cut stuf in laundry room
-still need batteries, charge controller, wire from genny to whereever I decide to put battery bank
I've lurked on this board for several years and love what I see. Hugh's design is great and I believe I can make my own someday also, but I probably won't get mine flying till sometime late summer 06. I'm quite the procrastinater so we'll see.
I do think hugh's design is great for 500 watts and to get more I think it'll take more rotors/stators pairs. the lenz2 is doing great as well,
but... if someone is looking for the silver bullet to get to say 2k watts in 10mph winds it'll be awhile. I my self hope to get there someday.