The video and blog post was Part 3 of the Experimental Wind Turbine Tower Project.
As seen in a previous video, the support tower was raised up into place. The 23-foot support tower would make the process of erecting the towers easier and safer. The plan was to come back, lower the tower for maintenance and remove some of the blades. But, as life goes, we had some commitments on the home front, lack of funds for gas, we didn’t get away for weeks.
But the delay did have a perk, the snow and ice finally melted on the logging road short cut that runs over the mountain. (shaves 45 minutes off the 4-1/2 hour drive.)
We finally arrive for the weekend and I notice right away that the wind turbine was missing a blade and the end of the support pole is really hacked up. Odd, the blades should have not have spun. The auto brake was applied to the controller before we left. I was really miffed, was the controller broken? The electrical cable looked OK. Read on to see what happened.
1. Search for the Missing Blade
I was curious to see what it looked like. Did a walk around and couldn’t find it. Decided I needed help, so I put a $10.00 bounty on the missing blade and my children suddenly got interested. A few minutes later, my son found it about 50 yards from the wind turbine. It had wedged itself into the ground by a bush. It hadn’t hit anything (or anyone) and my worse fears melted away.
2. Lower the Tower
The next step was to lower the old metal tower and figure out what went wrong. Used the existing tall, wooden, black pole already attached to the building. Attached a pulley at the top and a few feet below. Did a nice slow lower of the tower with the aid of the car.
During the time we were away from the cabin, we were told there was a big wind storm. A neighbour claimed he saw the wind turbines just spinning like crazy. The result was all the ends of the blades were all chipped and broken. The longest blade was 22-inches and the shortest was 17-inches. Thought it would be best to have all the blades the same length. It would prevent excessive vibration and wobble. Grabbed my hacksaw with a fine tooth blade and cut each blade the saw length.
4. Tree for a tower
As seen in previous videos, the thought was to use an existing dead/diseased tree for the tower. It didn’t cost anything and it was easy to find. If it didn’t work out, I could just cut it up and use for firewood. Most of the trees in my area are called Lodgepole Pine and stand about 50-feet in height.
During the winter, I found a fairly straight tree with hardly any branches. It was dragged out of the bush and laid up to dry. I measured the tree tower and figured it was about 53-feet long. I cut it down to 42′ feet and should work great.
5. Base for the tower
Didn’t have much time to rig up a proper base for the tower. Decided to use what was handy and utilise the existing 6 inch by 6-inch cedar base of the support tower.
Used a chainsaw to cut two notches for the 3/4″ threaded support bar. Drill a hole through the end of the tree tower and inserted the rod through. The rod would then sit in the groove.
6. The Black Knight
In honor of my younger days of watching Monty Python movies, I named the injured wind turbine, the Black Knight. The Black Knight would endure many fatal injuries, but would declare them “flesh wounds” and continue on. Thought it was a good fit for this project. Here’s a link to a clip about the Black Knight: https://youtu.be/zn82OJKrzzs
I also felt the wind turbine needed a spruce up and gave it a coat of black, rust proof paint.
7. The No Power Puzzlement
The tree tower would be 20 feet taller than the previous water pipe tower. The 10/3 SOW wire cable had to be removed and reconfigured to work with another cable. As I was unwrapping a piece of duct table from a joint, I saw that the male and female connect had come lose. Not sure how it happened, maybe when the ice pulled the tower over a bit and the vibrations just worked everything loose. It also explained why the blades were “free spinning”, there was no load from the battery bank and the turbine could do whatever. The best way to fix the problem, purchase a new 60-feet of heavy-duty cable. But, reality kicks in and I don’t have spare cash to spend on cable. (The cost is around $2.39 per lineal foot.) The piece I have now is 25-feet long and I’ll search Craigslist and garage sales for more. I would have to figure a new way to connect the cables and add a strain relief.
8. Raise the tree tower
The next step was to raise the new, taller tree tower. Attached ropes to all the pulley points. The other end of the ropes were then attached to tow hooks on the cars. Took the necessary safety steps and planned my route and add support in case the tower fell. I then proceed to test the tower out for sag. Tried twice and the tree tower bent like an archer bow. Hmm, a lot of weight there. I got this feeling that it wasn’t a good idea. I needed to add more support, change the place of the ropes on the tree tower. An extra pulley wouldn’t hurt either. As I was standing there working out the extras, it started blow a cold rain and I decided it’s going to have to wait for another weekend. I’d rather do it right the first time and prevent a disaster. I dismantled the tower, bunched up the wires and put the tools away. There will always be another weekend for projects.
Thanks for your patience and following our adventures.
Have not been to the cabin for a few weeks. There have been too many household projects that need to get done first. But, in between the daily chores, I’ve been messing around with gears made from plywood. Also wanted to incorporate more woodworking into the projects.
The plan for this project was to mount a large gear onto a wind turbine and then have a smaller gear attached to a DC motor. Hopefully, the wind turbine has enough torque to generate some decent power.
Might or might not work, but it’s fun to try anyway.
A video shot over the April 8th weekend. It’s about how to erect a support pole next to the existing big wind turbine tower. It’s one of the steps required to raise and lower the big wind turbine.
The support pole was from a large 25-foot tall tree that was missing 90% of its bark.It was dead and very dry inside. It made a perfect support tower for the existing and future taller tower.
A video about raise up a super tall tree into the air with a bunch of pulleys and then see how it functions as a wind turbine tower. The goal of the project was to source materials for a 50-foot tower, in this case, a skinny, tall, dead tree. Then use a living tree as the “crutch” to winch up and support the dead tree.
After testing out the new tower, the next step would be to attach a medium size wind turbine to the top of the dead tree. This would put the wind turbine high up above obstacles, hopefully make it spin faster and generate power.
Another benefit, since the tower is attached to another tree for support, no guy wires would be required and it would blend in with the background. The actual wind turbine unit would be on a slight angle so that the turbine would avoid the tree branches.
Tall trees? I have lots of tall trees to choose from. The cabin is located in a small forest that was devastated with an insect called the Mountain Pine Beetle. It killed off many trees in different stages of life. What I was looking for was a tree that measured roughly 8 inch wide at the base and as tall as a 50 feet. The type of tree is called a Lodgepole Pine (see link below). The trees do bend a bit, but are quite durable.
FYI: I’m afraid of heights. It scared the poop out of me going up the extension ladder to attach the chains to the support tree. It was only 22-feet up, but when the wind blew through the trees… it was a little nerve-racking.
The next step was to find a good place for the tower. It had to have a decent tree for support, get clean wind, close to the battery bank and could safely be raised and lowered. I also have to keep in mind for my neighbors. If I had a problem, could it fall on their cabin or outbuildings.
The current location is on top of the bunk house. Aside from the vibration noise, the roof ice has managed to dislodge a support pole. It sits only 15 feet up and gets little wind. Lowering it for maintenance is a little difficult too. My power pulley works great for lifting , but it doesn’t reverse in power mode. The user has to manually pull the wire off the spool.
For this test, my good neighbour lent a hand and we used his DC powered Warn winch on his jeep. It made the process of lifting the dead tree really easy and safe.
Watch the video and see what happens.
Link to Mountain Pine Beetle: https://en.wikipedia.org/wiki/Mountain_pine_beetle
Music credit: Bubblegum Ballgame by JR Tundra, YouTube Audio Library
A short video showing some of the basic steps required to hook up a small wind turbine to an off-grid battery bank.
Finally, I made some time to put up the small wind turbine tower. The deep cycle batteries in the main cabin needed to be charged. The snow covered solar panels were just not cutting it and not providing the necessary amps to charge the system. It was time to put up the small wind turbine and get some wind power!
Part of the problem was finding a suitable spot that was close to the batteries under the main cabin. I wanted something on the lakeside deck, but not fastened to the cabin. The vibrations from the wind turbine can be a little annoying at time.
Decided to construct a platform (or a sled) made out of spare 2″ x 8″ joists. I would work it into the existing firewood pile and use the wood as weight. If I needed to move it or add more anti-vibration material, no problem. If I built the base fairly solid and good support, might not need to use guy wires.
Next, was ta 8-foot tall support/guide for the 1.5″ tower pole. Created an open box with (2) 2 x 4s and (1) 2 x 6 pieces of lumber. Two 3/8″ diameter holes were drilled into the 2 x 4 for the support bolt and the secure bolt. The thought was to secure it to the cabin, but didn’t have that part thought out yet. Decided to sleep on it and see what comes up in the morning.
The next morning, after a cup of coffee, I devised Plan B. Erect a fairly tall pole (14′ – 20′) behind the base/tower. At the top of this pole would be a pulley (snatch block). A cable would go As I was searching around for a longer support pole, I looked at all the 40-foot tree around me and thought,” geez, this is what I’m looking for it costs nothing!” Grabbed the chainsaw and hiked out to the bush and cut down a 25-foot tall dead lodgepole pine tree. Dragged it back and removed all the sticks. The easiest way to get the support tree/pole thing into position was to hoist it over the roof and drop it down into position.