Author Topic: Light Wind Heavy Weight Turbine Project - as I build it.  (Read 175021 times)

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Steadfast

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #264 on: June 30, 2012, 04:12:51 PM »
here is the video....

At the end when I say "this will go the way of all flesh" I am referring to the arm on the shed
not the concrete foundation...

Just sayn
« Last Edit: June 30, 2012, 04:27:40 PM by Steadfast »
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Frank S

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #265 on: June 30, 2012, 04:20:13 PM »
105? it doesn't cool off to 105 until way after dark 30 here but then again I don't have to put up with humidity.
 But since it has been 120 to 130 in my office  because the AC let out the magic smoke a month ago on a really hot day I don't spend much time there.
 good luck on getting the Hbird going
I live so far outside of the box, when I die they will stretch my carcass over the coffin

Frank S

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #266 on: June 30, 2012, 04:33:51 PM »
so far everything is looking good  SF nice to seethe solar panel grabbing some rays
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birdhouse

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #267 on: June 30, 2012, 05:48:20 PM »
SF-

looks pretty darn good!  you're making leaps and bounds with your tower rig!

just a few observation...  make sure you wrap some bailing wire ect. around those screw in shackles.  they can easily unscrew themselves as the tower starts vibing from energy production. 

also, the screw links where your raising guys meet your tower should have some medium strength loctite on the threads...  or just remove them, and run the guys straight to the tower. 

basically anything that can be removed, should be, less potential points of failure, and any needed hardwear that doesn't have a clevis/safety clip/means to keep it tight, should have something.

i liked the chicken video as well!

adam 

keithturtle

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #268 on: July 01, 2012, 02:31:17 AM »



just a few observation...  make sure you wrap some bailing wire ect. around those screw in shackles.  they can easily unscrew themselves as the tower starts vibing from energy production. 



And make it stainless baling wire- I know of a 10kW bergey mill lost due to a non-stainless cotter pin that failed after a few years in the weather.

After all, let's be optimistic that your mill will be up for a while...

Turtle, still at it
soli deo gloria

just-doug

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #269 on: July 01, 2012, 12:58:53 PM »
clevis pins,screw-in or cottered,are notorious for working out just when you get comfortable with the set-up.i say get it broke in good and go back and tack-weld everyone of them.

Steadfast

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #270 on: July 01, 2012, 06:06:40 PM »
On Saturday night I painted the mast black, and got eaten alive by mosquitoes too!

Todays blazing weather drudgery made yesterday look easy!

But here are the results for SUNDAY!

Because we were looking at another 100+ degree 90% humidity day,
I once again woke up at 4AM and hit the back yard by 5am.

yes,  :-[ I skipped Church...
but that would not have happened had the weather not been so threatening and the Task so daunting!


I strapped the mast to 2 moving dollys and started to work on the HBird
while I waited for my good and faithful father in law to arrive.

I clamped some thin boards to either side of the bent turbine hub to use as a lever.
and tugged this way and that until I got things straightened out.


when the father in law (FIL) showed up, we installed the winch.
We had to drive all the way to Lowes to get the bolts and waste 1 hour, but it is done.

By the time we made it back, the sun was blasting at 95 degrees. at 9AM..  :o

so, we started to moved the mast into place with a dolly strapped to each end
and managed to Semi-Truck park it at the new Hinge, which I also painted black earlier that morning.
we were so wiped out and embarrassed by the raw jerry-rigging of it all, that we did not get any pictures of that exhausting fiasco.

once I hooked up the block and tackle to the winch and almost passed out (seriously) in the sun doing it
we took a long gator-aid and water break, and began the first test lift.

You will notice the LBird snuck onto the mast to function as a "fancy wind sock".
Because the new winch was laughing at the weight, we stopped at this point
to repaint the mast where the dollys tore up my awesome paint job.

For you Safety nuts: once we resumed. my FIL used a tree for tension on the guy cable on one side,
and my handy neighbor did the same on the other side,(both wore Gloves) while i cranked the winch FOREVER.
no one was within 15 feet of being under the mast as it went up.

The winch stand didnt even shutter once! The winch mocked this tiny challenge to its SHEER POWER.
The two Snatchblocks worked flawlessly. The foundation was silent strong and solid.




These two photos are of the guys anchored 6ft up a tree and clearing the sheds roof.
Did I mention that the normally exasperating chore of adjusting guys is a total pain in the butt in 100+ weather
when you just want to quit and go inside. and get the burning sweat out of your eyes.
no?? well... it IS!



And two more goovy pictures of the mast in test raise mode.


Next week end, perhaps on the 4th of July,we will finish repairing the HBird and get it FLYING!
Flying a wind turbine for the first time! What a great way to celebrate our Glorious country's Independence Day!
"who needs fireworks!? Just look at that Turbine spin!"
.
.
« Last Edit: July 01, 2012, 06:25:26 PM by Steadfast »
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birdhouse

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #271 on: July 01, 2012, 06:51:44 PM »
NICE WORK SF!!!

intersting guy set up, but it seems to work great!  it must feel really good to have made some trouble free progress! 

does the wife seem happier?

kudos!

adam

spottrouble

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #272 on: July 01, 2012, 06:59:18 PM »
I see the guy wires for either side, and the guy wires going to the gin pole/winch, but no guy wire going in the fourth direction? Whats up with that?

Kristi

Steadfast

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #273 on: July 01, 2012, 07:01:58 PM »
Yes... she was very happy to see some light at the end othis tunnel....
Or some turbine at the top of a working tower...

Me.. I find it good to be on the working side of physics... for once!

By Hook or by Crook - Prayer, Persistence and Tenacity will win the day!

Steadfast

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #274 on: July 01, 2012, 07:03:40 PM »
I see the guy wires for either side, and the guy wires going to the gin pole/winch, but no guy wire going in the fourth direction? Whats up with that?

Kristi
because there is no fouth direction....?
By Hook or by Crook - Prayer, Persistence and Tenacity will win the day!

Frank S

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #275 on: July 01, 2012, 07:17:22 PM »
I see the guy wires for either side, and the guy wires going to the gin pole/winch, but no guy wire going in the fourth direction? Whats up with that?

Kristi
because there is no fouth direction....?
ARE you saying then that you have the set up on a 120Degree split? 0/120/240?
 
 or are you at 0/90/270 without a 180 ?
I live so far outside of the box, when I die they will stretch my carcass over the coffin

tanner0441

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #276 on: July 01, 2012, 07:32:35 PM »
Hi

Well done it looks good, only a couple of comments.  You have three brackets for the guys, not a problem but, two of the brackets have a bending moment on two oh them.  It would have been better to have welded the brackets, which don't continue the direction of ther guy wires, should have been welded on at an angle so the loading puts the welding under tension not bending loads. If the blades are on the turbine will they clear the top guys, and a quicky put a dab of weld on the threads on the turnbuckles to stop any chance of screwing right out.

It looks tidy and plumb in the photograph.  Your weather made our news broadcasts, apparently one in three people in the US is experiencing the worst heatwave since the 30s, and there are a couple of million people without power after the storms that go with it. Our weather is the oposite in the east we have had storms like you get in the mid west, and we are being rained on all the time. I sprayed a hew hood for my motor home to had to spend a day and a half flatting it back down again. So get the turbine flying ready....

Brian



Frank S

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #277 on: July 01, 2012, 08:01:56 PM »
Once again though, now that you know your procedure that you must use to stand the tower. Before you actually raise the Hbird . Raise a 60 pound sack of dirt at least to 60 degrees.
 on your turn buckles after you get your tower in its final life long position . thread a piece of your 1/4" cable through the  guy thimble then through the buckle body then through the opposite end  then use a cable clip to  secure the 2 ends to each other. this is easy to remove when you need to adjust your turnbuckles and at the same time will insure they can not unscrew or should one break you still have a semi secured guy wire.
I live so far outside of the box, when I die they will stretch my carcass over the coffin

Steadfast

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #278 on: July 01, 2012, 08:09:03 PM »
I see the guy wires for either side, and the guy wires going to the gin pole/winch, but no guy wire going in the fourth direction? Whats up with that?

Kristi
because there is no fouth direction....?
ARE you saying then that you have the set up on a 120Degree split? 0/120/240?
 
 or are you at 0/90/270 without a 180 ?

trangle...
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definitionofis

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #279 on: July 02, 2012, 07:39:50 AM »
Is the triangle equilateral or did you go with something less than equal because the tower is located eight feet from the property line?

Steadfast

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #280 on: July 02, 2012, 10:15:43 AM »
Is the triangle equilateral or did you go with something less than equal because the tower is located eight feet from the property line?

it is equilateral-ish...  give or take a few degrees based on tree location.
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Steadfast

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #281 on: July 02, 2012, 10:45:03 AM »
oops double post...sorry about that...
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Steadfast

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #282 on: July 02, 2012, 10:56:53 AM »
Here is the corrected image missing from the earlier post:

The winch stand didnt even shutter once! The winch mocked this tiny challenge to its SHEER POWER.
The two Snatchblocks worked flawlessly. The foundation was silent strong and solid.


By Hook or by Crook - Prayer, Persistence and Tenacity will win the day!

midwoud1

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #283 on: July 02, 2012, 04:24:43 PM »
Steadfast.

That`s  a whole lot better. Wish you fysical , Psychical and Electrical  power.

  - Frans -

Steadfast

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #284 on: July 02, 2012, 09:39:43 PM »
my mast is now 35ft tall not 30ft tall... 
which means my 40ft of 14 AWG drop line is also too short. 

Soooo, I had to buy a new one.... >:(


But THIS one is 50ft 0f 12 AWG...


See I AM LEARNING!

The old one will make an awesome drop cord.
.
.
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birdhouse

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #285 on: July 02, 2012, 10:05:25 PM »
SF-
bummer about the short cord!  true though, it will make a really nice extension cord!  you could even put a strain relief end on it with a 4square box with four outlets in it! 

are you batteries going in the shed? 

i like to put a reinforced hole in the side of the tower for the wires to exit.  (pictured below)  this way, as you walk by, you can grab the wire and check for twists really easily!  like mentioned, a hole saw makes for quickish work of big holes in steel!



adam

Steadfast

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #286 on: July 02, 2012, 10:22:17 PM »
SF-
bummer about the short cord!  true though, it will make a really nice extension cord!  you could even put a strain relief end on it with a 4square box with four outlets in it! 

are you batteries going in the shed? 

i like to put a reinforced hole in the side of the tower for the wires to exit.  (pictured below)  this way, as you walk by, you can grab the wire and check for twists really easily!  like mentioned, a hole saw makes for quickish work of big holes in steel!



adam

Smart....   ;D

But I am DONE making my Father In Law weld! 
At least for a little while.. ;)

I am going to let it come out of the 3" space at the bottom of the mast.

.
.
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Watt

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #287 on: July 02, 2012, 11:25:30 PM »
Be careful letting it come out the bottom, you have two bolts which may cause some rub/cut through of wire insulation.  I'd reconsider the welder....  Wish you the best. 

Steadfast

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #288 on: July 03, 2012, 08:20:54 AM »
This is the Solar Panel I ended up buying on EBAY.
I will permenantly install it on the sheds roof, to back up my Turbine...

http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=320937207807&ssPageName=ADME:L:OC:US:3160

100Watt 12Volt Solar Panel 100W 12V Poly crystalline.
$182.63
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Frank S

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #289 on: July 03, 2012, 10:02:47 AM »
SF, slide a couple feet of old garden hose  over the drop line up into the bottom of the mast to protect it from chafing
I live so far outside of the box, when I die they will stretch my carcass over the coffin

Steadfast

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #290 on: July 03, 2012, 10:04:13 AM »
SF, slide a couple feet of old garden hose  over the drop line up into the bottom of the mast to protect it from chafing
Smart!  A great solution!
By Hook or by Crook - Prayer, Persistence and Tenacity will win the day!

just-doug

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #291 on: July 03, 2012, 08:20:26 PM »
cheating guy angles with 4 guys can be done succsefully,but cheating the angles with only three guys is another failure in the waiting.

birdhouse

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #292 on: July 03, 2012, 08:37:55 PM »
i like to use the garden hose idea at the top of the tower also.  helps keep the cable in good shape where it rubs from the yawing.  a hose clamp of all things keep the hose from sliding down the wire and getting stuck inside the tower.

adam

definitionofis

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #293 on: July 04, 2012, 10:34:48 AM »
Is the triangle equilateral or did you go with something less than equal because the tower is located eight feet from the property line?

it is equilateral-ish...  give or take a few degrees based on tree location.

Are the guy-wires, which are near the eight foot property line, up high in the trees, instead of on the ground?
I think that would be a good idea.

tanner0441

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #294 on: July 04, 2012, 11:17:23 AM »
Hi

To elabourate on that last comment.  The guys should really all be the same length and angle down from the point on the mast. By anchoring up a big tree you can maintain the angle but shorten the length.  The angle of separation is more critical and any more than a few degrees, from 120, can result in an asymetrical suport of the tower, not too much of a problem with an antena mast but with the yawing forces on a turbine mast, especially in turbulant conditions, could allow excessive whip and movement on the mast and resulting loading on the anchor points.

The brackets the guys attach to on the mast not being at the correct angle to the guys would come under a lot of lateral pressure which puts stress on the welds.  The thing to remember is the forces acting on the mast are 24/7 as long as the wind is blowing and they are not a steady loading in one dirrection. Find someone with a turbine up and running and ask if you can visit them when there is enough wind to make it work and put your hand on the mast and feel the vibration and movement.

As already said your mast looks good and well made. The very first critisism on your old mast was regarding the way you wanted to hold it up.

Brian.

tanner0441

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #295 on: July 04, 2012, 11:55:53 AM »
Hi

I just found this statement by spareweb on another thread on here....

I went with 3" pipe for my 40' tower, to hold a 8-foot diameter turbine.  You would think that's heavy enough, but it actually wiggles and dances when the turbine is running full-tilt.  I guess if I had to measure, it's 1/2" flex, half-way between guy wire attachments, which isn't a lot, but certainly visible to the naked eye.




Brian.


Steadfast

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Re: Light Wind Heavy Weight Turbine Project - as I build it.
« Reply #296 on: July 04, 2012, 09:27:06 PM »
IT...IS....FINISHED!
IT...IS...VICTORIOUS!
IT...IS...FLYING!!!
;D

I have MANY Photos coming... But first A Video...

Raising Steadfast's Turbine Part1:
« Last Edit: July 04, 2012, 09:31:31 PM by Steadfast »
By Hook or by Crook - Prayer, Persistence and Tenacity will win the day!