HowTo: WinDIY - Assembling the prepared components

So that the assembly articles for WinDIY do not become too extensive, I have divided the assembly into several articles. A specific component, such as the wing, is built per item. Of course, these individual components have to be brought together at some point.

That's what this article is intended for.

This article is intended to help you connect the individual prefabricated components.

Safety instructions

I know the following notes are always kind of annoying and seem unnecessary. Unfortunately, many people who knew "better" have lost eyes, fingers or other things due to carelessness or injured themselves. Data loss is almost negligible in comparison, but even these can be really annoying. Therefore, please take five minutes to read the safety instructions. Because even the coolest project is not worth injury or other trouble.

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Required tool:

Required material:

You can find the plastic parts shown in the Nerdiy GitHub. Here:

I printed the parts with the following settings.

  • Perimeter: 5
  • Infill: 30%

The screws should preferably be made of stainless steel so that they do not rust due to moisture.

Attach the main axis cover

After construction, the main axis is exposed to the ambient conditions quite unprotected. Wind, rain and sun can therefore easily reach the main axis. In order to protect this a little better, a cover is attached in this step.

So that the cover can be put on, you should have already connected the main axle to the hub.

In order to be able to put the cover on you will need the cover, two M3x30 countersunk screws and two M3 nuts.

Now insert the screws from the outside into the screw holes shown.

Then screw the M3 nuts onto the screws on the inside and glue them into the recesses provided with a little hot glue as shown.

Close-up view of the M3 nut fixed with hot glue.

Close-up view of the M3 nut fixed with hot glue.

After the hot glue has cooled, you can unscrew the screws again.

Now bring the wing slots of the hub into the position in which they are at their maximum position.

Only then can you put the cover over the main axis.

This should be pressed just behind the hub onto the main axle holder.

View from above (cover not yet fully attached).

View from the side (cover not yet fully attached).

View from the back (cover not yet fully attached).

As soon as the cover is completely put on, the main axis should be completely covered. The wings do not rub against the cover.

Now put the M3 screws back in and screw the cover to the main axis bracket.

Make sure that the front of the cover does not rub against the hub.

Install “equipment carrier”.

The equipment carrier is the part on which the generator including the brake actuator, as well as the pitch actuator and the wind vane will later be attached. This basically consists of two 75cm long aluminum profiles, which are screwed to the base bracket of the main axis bracket.

To assemble the equipment rack you need two 10x10mm 75cm long aluminum profiles, two M3x16 countersunk screws, two M3x50 countersunk screws and two M3 nuts.

Lay the unit on its side as shown.

Now insert the M3x16 screw...

... into the screw holes in the base bracket.

To do this, insert the screw from the outside and...

…screws on the M3 nut from the inside.

Then pull the M3 nut on the screw into the recess on the inside.

Then you can put it in the free holder...

... insert the 10x10mm aluminum profile and clamp it with the M3 screw.

Make sure that the aluminum profile protrudes 5mm on the front.

As soon as you are sure that the aluminum profile is in the right place, you can finally tighten the M3 screw.

Now put the unit back up.

Now you need an approx. 10cm long 3mm drill.

Use this to drill through the aluminum profile of the main axis bracket as shown and then through the aluminum profile of the equipment carrier.

Both aluminum profiles are completely drilled through.

Have you drilled through both aluminum profiles... can insert the M3x50 screw...

...and screw it on the underside with the M3 nut.

This should retract into the recess in the base holder.

The first aluminum profile is now fixed.

Now repeat these steps with the second aluminum profile on the opposite side to complete the construction of the equipment carrier.

Install the generator cover

The generator is also protected with a cover.

To do this you need the printed cover of the generator, two M3x10 countersunk screws and two M3 nuts.

Close view of the required screws.

Now insert the M3 screws (as usual) into the recesses in the cover of the generator.

Close view of the inserted M3 screw.

View of the two screws inserted.

Now set up the main axis including attachments as shown...

...and puts the generator cover over it.

To do this you have to pull the cover apart slightly at the bottom.

The cover should now rest on the aluminum profiles of the equipment tray as shown.

On the front, the cover pins should...

...can be inserted into the aluminum profiles of the equipment tray.

View of the inserted cover.

Once everything is in position, you can clamp the M3 screws with the aluminum profiles of the equipment carrier.

Another view of the attached cover.

Install the generator and brake actuator unit

You should have already prefabricated the unit consisting of the disk generator and brake actuator. In this step, this is now mounted on the device carrier.

To do this you need the prefabricated unit consisting of a disc generator and brake actuator.

Now prepare its assembly by inserting the M3 screws...

...insert it back into the screw holes provided.

Then you can push the unit onto the equipment carrier from behind.

Make sure that the push rod for adjusting the blade pitch is guided through the guide in the middle of the generator.

Now push the unit forward as far as it will go. The mechanical coupling of the generator should be completely inserted into the coupling piece of the main axis.

You can now fix the unit by clamping it to the aluminum profiles of the equipment tray using the screws you previously inserted.

another view.

Install the pitch actuator

The pitch actuator is supposed to move the push rod back and forth. This ultimately allows the wing angle of attack to be adjusted.

To do this you need the parts shown.

But let's start with the parts shown here.

First insert the M3x20 countersunk screws through the stacked parts as shown.

View of the stacked components.

This unit will later be used to clamp the large gear on the threaded rod.

Then screw the components together with three M3 nuts...

…on the back side.

Now you can also use one of the M6 nuts...

...insert into the corresponding recess.

we continue with the “big gear”.

Here too, place the M6 nut in the recess provided.

Now put the stacked and screwed together washers including the M6 nut onto the push rod.

Then screw the large gear onto the push rod.

Before you can put the pitch actuator on the device carrier... must first equip this with four M3x16 countersunk screws including M3 nuts.

Set this as before for the generator... the left and...

…right side of the base.

View of the prepared mount.

Now insert the pitch actuator from behind onto the aluminum profiles of the equipment carrier.

Then screw the push rod into the anchor point on the top of the pitch actuator.

So far your structure should look like this.

The pitch actuator should now sit on the equipment carrier with the screwed-in push rod so that the wings (as shown) are in the sailing position.

Then you can also clamp the base of the pitch actuator on the device carrier.

Other view.

Now you have to turn the M6 nut that you previously inserted into the large gear to the position shown.

Then bend the wiper of the pitch wiper resistor a little to the side... that the big gear can get past it...

...can be pushed onto the M6 nut.

Then you can also turn the unit consisting of the three remaining discs with the M6 nut towards the large gear and thus clamp it on the push rod.

The grinder of the pitch grinding resistance can then be bent into the guide as shown.

When the gear is rotated and the push rod is moved forward or backward, this is taken along and thus signals the position of the pitch position.

To secure the large gear you need three M3x25 countersunk screws.

Insert this through the large gear as shown...

...and secures it with...

...screw it to the other discs before being twisted on the push rod.

To do this, you can insert an M3 nut into the recess at the location shown.

The easiest way to do this is with needle-nose pliers.

That was it for the structure of the components and the integration on the device carrier.

Other view.

Other view.

Other view.

Have fun with the project

I hope everything worked as described for you. If not or you have questions or suggestions please let me know in the comments. I will then add this to the article if necessary.
Ideas for new projects are always welcome. 🙂

PS Many of these projects - especially the hardware projects - cost a lot of time and money. Of course I do this because I enjoy it, but if you think it's cool that I share the information with you, I would be happy about a small donation to the coffee fund. 🙂

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