Wind Turbine Plans: Starting Guide

Generate Wind Turbine Airfoil Blade Cross-Sections

Generate Stencils For Your Airfoil Cross-Sections: Use the Chord Section Generator in the Trial Range for Free.
Starter Guide
Print the bladecalc plans and cut out each chord section
Using the chord sections to manufacture wind turbine blades.
Paste the shapes on balsa (at least 3 mm thick (0.12 inch) and superglue adhesive the entire piece. Cut out each balsa section using a scalpel.

Free Trial: Cord Section Generator

How to use the pdf plans from the warlock blade design software.
Custom chord sections outside this range can be purchased from $4.95, please send us your specifications. Follow the link below to order. Larger chord sections (beyond A0) may require up to 28 days for manuscript adjustment
1.  Print the bladecalc plans and cut out each chord section.
2.     Paste the shapes on balsa (at least 3 mm thick (0.12 inch) and cover the entire piece with super-glue adhesive.
3.      Cut out each balsa section using a scalpel.
5.    Create a root using a solid piece of plastic or sheet metal with a thin rod to align the crosshairs drawn on each section.
4.      Make a hub from wood with a thickness to match section 1.
Make a hub from wood with a thickness to match section 1.
Create a root using a solid piece of plastic or sheet metal with a thin rod to align the crosshairs drawn on each section.
6.       Glue the root into the hub.
7.     Position each balsa section at the radius shown on the plans and glue (or silicon) them in place.
If the mold is too thin, fiberglass the outside of it before pulling it apart. When dry, pull the mold apart and sand the insides smooth.
Apply a layer of wax to the inside of the mold. (Layers of hairspray or shellac also work). Fill the inside of both mold halves with at least 4 layers of fiberglass matting. For a 0.7 meter (2.30 ft) blade use at least 375g (13.23 Oz) of resin per side (steps 1-2). Clamp both halves together when the resin has reached gel point (steps 3-4).
14.   If the mold is too thin, fiberglass the outside of it before pulling it apart.
15.  When dry, pull the mold apart and sand the insides smooth.
16.   Apply a layer of wax to the inside of the mold. (Layers of hairspray or shellac also work)
17.     Fill the inside of both mold halves with at least 4 layers of fiberglass matting. For a 0.7 meter (2.30 ft) blade use at least 375g (13.23 Oz) of resin per side (steps 1-2).
18.  Clamp both mold halves together when the resin has reached gel point (steps 3-4).
After 72 hr, pull both halves of the mold apart. If a plaster mold sticks shut, the plaster can be dissolved with dilute vinegar or hydrochloric acid.
20.    Sand the blade smooth and fit a solid hub piece.
19.  After 72 hr, pull both halves of the mold apart. If a plaster mold sticks shut, the plaster can be dissolved with dilute vinegar or hydrochloric acid.
Frequently asked questions about plan orders, blade design, electrical work and generator matching can be found on our Q&A pages.
Free: Chord sections for 2 or 3 blade wind turbines with a radius between 0.70 and 0.80 meters (2.30 to 2.62 ft) at TSR 7 to 8.
Custom Wind Turbine Blade Plans Available from $4.95
Free plans for 500 W blades
with each purchase.
Preview of bonus material included with every purchase
Design custom blades for your generator and calculate power output at each wind speed.
Free sample chord sections can be generated for 0.70 m to 0.80 m blades (550 Watts - 710 Watts).
Blade Calculator
The root section is glued into the wooden hub
Airfoil cross-sections are glued along the length of the root.
Wind Turbine Articles in PDF
10 kW, 15 Phase Axial Flux Pancake Generator for 2-Blade Wind Turbine [PDF]
10 kW (13 m/s), 5 Metre Diameter Carbon Fibre Blades for Wind Turbine [PDF]
1.8 Metre Diameter Carbon Fibre Wind Turbine Blades and Generator [PDF]
1.4 Metre Diameter 3-Blade Wind Turbine Construction  [PDF]
Chemistry PDF Articles for Download
Microwave Chemistry Reactor [PDF]
Dielectric ‘Loss Factor’ (e’’) Measurement Over RF Frequencies Between 0.1 - 40.0 GHz for Common Organic Chemicals [PDF]
Deconstruction of a 300 MHz Cryomagnet for NMR Spectroscopy [PDF]
Microwave Chemistry Reactor
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Design custom blades for your generator and
calculate power output at each wind speed.
Free sample chord sections can be generated for 0.70 m to 0.80 m blades (550 Watts - 710 Watts).
Blade Calculator
Use fiberglass gel-coat or epoxy to cover the entire blade skeleton.
8.   Use fiberglass gel-coat or epoxy to cover the entire blade skeleton.
 Glue acetate sheet to the top and bottom of the sections.
9.     Glue acetate sheet to the top and bottom of the sections.
Seal the acetate sheet with aluminium tape (or waterproof tape).
10.    Seal the acetate sheet with aluminium tape (or waterproof tape).
Make a border (molding clay is shown below) to support the casting mixture (plaster/gauze shown below. Can also use plaster/fiberglass or fiberglass/fiberglass resin).
11.     Make a border to support the casting mixture. Molding clay is used for the border in this example.
The casting mixture we use here is plaster and gauze. Alternatives include plaster/fiberglass or fiberglass/fiberglass resin.
12.    Fill the mold with the casting mixture and allow to dry for at least 48 hr.
Fill the mold with the casting mixture and allow to dry for at least 48 hr.
Free sample chord sections available for blades between 0.70 m and 0.80 m.
Custom Wind Turbine Blade Plans Available from $4.95
Custom Wind Turbine Blade Plans Available from $4.95
Free plans for 500 W blades
with each purchase.
Preview of bonus material included with every purchase
Make a cast of the other side.
13.    Make a cast of the other side.
500 W Turbine Plans
Included
With Your
Order
500 W Turbine Plans
Included
With Your
Order
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1.4 Metre Diameter 3-Blade Wind Turbine Construction
1.4 Metre Diameter 3-Blade Wind Turbine Construction