As I was predicting, the blades not spinning fast enough was the real problem. I lowered the battery voltage from 3.59v to 3.38v and then reduced the air gap. This made it cut in at a much more reasonable wind speed (probably 9-10 mph). I need to make a new base for it since it likes to warp when it gets hot and the bearing supports end up becoming non-perpendicular to the shaft and there ends up being extra drag. I also need to do a bit more clearancing in the alternator where the magnets hit the glue. It made 1.75 ah in 4 hours today, which may not sound like a lot, but it's better than the last few attempts.
I still want to make some new blades since these still seem fairly lackluster.
