Hi caseyjt -
"I'm convinced on the 48 volt."
I don't think you'll regret that in the long run. A system is fairly expensive it $$ and time, the cost of the inverter is a very small part of it. Plus - if you get a good inverter it'll most likely contain a powerful charger which is nice.
"I can have the plate steel laser cut locally after I purchase the hub and spindle (I'll go with your suggestion on one a little larger) also local. Dan you commented on larger diameter rotors. I would suspect it wouldn't need to be much larger. In reading about your 17 ft machine you ended up with about 3/8 gap at the lower end of the magnets. What would you have preferred? 1/2 inch? 5/8 inch?"
I wouldn't change things too much only because I know this combination of things works. But a bit larger would help - not just because the magnets are too crowded, but also it'll allow for a larger hole in teh stator. As mine was, the coils are of such size that they come very close to the hub. I would advise a larger spindle/hub - and youll want more room in the stator to accomodate that.
" Any other tips on replicating your 17 footer will be helpful. I did read about your blades hitting the tower. How do I determine what is enough angle and what is too much?"
5 degress would be plenty.
"It's hard to take a wag at a picture. Oops, but good the blades where that flexible, a testiment to good cedar laminated blades. "
"The blades are holding up real well - and we've had lots of violent wind up here latetelty. I'll try to keep a good photo log book as I go along and spread the good news to my friends and neighbors albeit I own the hill...FYI, even though we get good winds I want a low wind performer such that the 17' will produce and provide adequate power for my office and a few outside florescents and expand from there. Mostly this is for fun...and hopefully helps in retirement, if I make it."
Good - it's a good way to go into this 'for fun' - because it's not always cost effective compared to grid power.
I'll post more on this later in the week - but.. I took my machine down today because a weld broke in the tower. We fixed the tower , but the machine itself has problems. The bearing has loosened somewhat (bigger spindle and hub I should've used). In a large diameter axial machine with the airgap tight - a bit of bearing play can trash the stator pretty easily.
Also - the way I cast the magnets in this one isn't going to work out. Some of the resin has broken and there are loose bits between some of the magnets (making a funny sound every time it goes round which I've noticed lately). Some of that resin has hit the stator and rubbed it through to copper in 1 spot. A couple of the magnets have broke loose and moved out about 1/4".
Basicly Monday we'll overhaul this machine and hopefully you can learn from my mistakes! It's been good for a year - but I expect if we dont fix it up it wouldn't last another month without trashing the stator.