1/2 scale Aermotor windmill

[Aris468]

I've been thinking of building a 1/2 scale Aermotor windmill, hoping it will function like the real thing. I'm thinking, wheel is 48in in diameter, tower is 15ft tall, and centerline is 16ft. I still have to look if I can access a foundry so for now, I think I have to fabricate everything from plate, sheet, and off-the-shelf structural parts. I also don't have access to an actual, working Aermotor which I can inspect up close so I'm hoping someone here can give me advice. What kind of slew bearing should I use where the mast meets the motor and should it be lubricated or sealed? Any tips on motor attachment to prevent the assembly from lifting off the mast? And any other initials details I should consider or be aware of to get started properly on this project? I'd appreciate getting your insights!

 

[James D.]

Oooh, that's a fun project you got there. Check trailer hub assemblies for the bearing too since they're cheap, built to spin, and already sealed.

 

[OldWindWorks]

That sounds like an awesome project! A buddy of mine actually made a half-scale windmill with some custom parts not too long ago.

For the slew bearing, it's best to go with a babbitt-style one (something like the Aermotor #752) that's lightly oiled and easy to maintain. Make sure to clamp the motor down tightly so it doesn't lift.

Also, be sure to use materials that resist corrosion and set up a routine for lubrication. You might want to take a look at the Aermotor manuals online for more detailed advice.

 

[Randisson]

Trying to replicate a functional Aermotor at half-scale without access to original parts or proper castings is setting yourself up for endless tweaking. Fabricating from plate and off-the-shelf parts sounds practical, but you'll fight balance and wind loading issues nonstop