Carving Blades

[luv2weld]

This is the process I used in carving blades.

I used the plans in Hugh Piggott's book "How to build a Wind Turbine" for deciding

how many stations I needed and how to layout the lines.

I used the blade program that I got from Ed at Windstuffnow for calculating the length,

width, etc.

Thanks to Ed and Hugh for all their help and knowledge.

The blades are sized for an Ametek 99 that Birdmanjack needed a set of blades for.

We made a trade----I needed 12 inch diameter steel plates, and Jack needed blades.

The first picture shows where the blade starts after all planning and calculating. (You have to figure out how much blade you need for the generator you want to build. Or you decide on your blade size and then build the generator to match it.) These are 10 inches wide by 1.75 inches thick and were cut for 5 foot length. (10 foot diameter)

The next step is after a little bandsaw work. I know the picture is sideways--

but that's the way my world is!!

Then layout the lines for contouring.

I tried all kinds of ways to get rid of the excess wood. Notch with a saw, then hammer and chisel to remove the waste.

Then use a hand plane to smooth it down.

I also tried using a device that attaches to a handheld grinder. (It is sold under several names---The one I used was called Arbortech.)

I also did the intense arm workout called using a drawknife.

Then the final tapering and smoothing was done with a belt sander.

The final product after finish sanding is shown in this shot. It looks amazingly like a birds wing. Remember this was done using the instructions in Hugh's book.

But I can tell you for sure, the next set I carve will be done using Oztules great idea of trimming down the waste with a chain saw.

Thanks Oz. My arms thank you too!!!!

Ralph

[oztules]

Yes, yes, yes,

If I knew how too, I would put this to the front page.

Darn nice job, and beautiful looking profile you have there. I did my first 8 foot set exactly like that (without the draw knife of the bandsaw though) If you can imagine another one and a half feet per blade on top of what you just did, of cutting and chiseling and everything seems so much bigger too on a larger set.... thats why I needed a different way, I was such a sniveling wimp, I couldn't face up to it a second time.

That Arbortech thing is the nastiest piece of work I have ever had the privilege to use. It is downright nasty.... but does it work well or what... gotta luv it.... but I'm fearful every second the switch is turned on.

As it is for an iron cored machine, you need that lovely wide root for start up.

With a dual axial, you need only worry about the top 2/3 to 1/2. It starts regardless how bad the root is. Mine is woeful aerodynamically for the first 2 feet or so, I went for strength, and it starts in a breeze I can barely feel, the the business end is properly formed and works very well.

I think getting the "idea" of how the blade is made /angled, is as hard to imagine as the furling system is to get the mind around. But, once seen in real life, they are simple.

Your gonna cry when you see how easy it could have been. Worse still the second is easier, and the third easier still. If you make your jig a little bit better than mine, you can turn them out all day long. One more thing, I found that not cutting the blade shape, but rather using full square blanks is easier than cutting out the blade shape first. (the sideways picture). It allows you to jig it up better (indexing if you will).

Great work

........oztules

[kurt]

like i told tom if you make a diary front page it messes things all up unless you wait until it has been bumped out of the diary box then you can do it.... see me on irc i will explain allot of editor things including how to make things front page.  

[luv2weld]

Oz,

Thanks for your kind words.

That Arbortech thing is the nastiest piece of work I have ever had the privilege to use. It is downright nasty.... but does it work well or what... gotta luv it.... but I'm fearful every second the switch is turned on.

Boy are you right about that Arbortech thing!!!!!!!!

It's like trying to stick a wet noodle up a wildcats butt!!!!!!!

You just hang on for dear life and hope it doesn't get away from you!!!!!

Ralph

[richhagen]

Nice description of your carving process, and your blades look excellent.  





A smaller CNC'd version of your birds wing.

[SparWeb]

I feel less of a fool now, because my first try cutting blades with power tools was with a 17" circular saw.  I made guides like Oztules did, but everthing was spaced wide apart to make clearance for the saw disk, and the saw repeatedly grabbed, since I was holding it up in the air.  Not safe, nor quick.  Went back to the drawknife after that.

Nice end result.  Always satisfying, no matter how much work it took.

[scottsAI]

How about posting a story with a link to diary?

Post can be put on front page and later removed when the Diary can be place there or not.

Have fun,

Scott.

[oztules]

Scott,

I thought the same thing. I did this with one of my diaries that got lost in the system somewhere.

Quick title, good tease picture from the story and a link to the diary story proper.

Wouldn't even bother to delete link when finished with.

Great minds th..... no I won't bring you down like that.....

......... oztules

[luv2weld]

Thanks to Rich & Steven for the kind words. They are appreciated.

And after carving a few more sets of blades with a draw knife,

we'll be ready for the Arm Wrestling Championships!!!!!!

Ralph

[phil b]

That Arbortech should require a license to drive. I tried them too. Now, I use sanding disks attached to a hand held grinder. They come in 30, 60 and 90 grit. Much easier to control.

[getterdone]

the band saw you used to cut the blanks out., do you have plans to build it?, looks home built. i've been wanting to build one. if you have the plans could you share them?  thanks for responding. i can be 'e' mailed at j.ossowski@yahoo.com

[luv2weld]

Here are several links for "build your own" sawmills.

Google will bring you a ton of sites.

The first one is selling plans for $8.44!!!

http://store.payloadz.com/str-asp-i.45160-n.Plans_to_build_your_own_Band_Sawmill_eBooks_-end-detail.
html

http://www.tractorbynet.com/forums/build-yourself/19114-portable-sawmill.html

I bought the plans for mine from:

Bill Reeks Sawmills

7104 US Hwy 231 S

CROMWELL, KY 42333

Tel: 270 274 3361

Or check out his homemade saw from "junk" in the March/April 1996 issue of Countryside

He also has several articles in Farmshow magazine.

http://www.farmshow.com/

Ralph