I found a way to make a super cheap wind turbine from two USB fans, 3 metal rods, some roof flashing, and not much else. Basically this will be the rotor/generator in my hexagonal design shown in the previous pages.

The first step is to cut three metal rods or tubes into 8"  lengths. The diameter has to be small enough to tap 6-32 screw threads. In my case I used 1/4 inch aluminium rods. 

Next, each end of the rods (or tubes if they are small enough for 6-32 tapping) are tapped about 3/8 inch deep. We'll be using 1/2 inch long machine screws.

 

Use a pair of star lockwashers on both sides of the circular frame to nicely sandwich the assembly.

I tried making blades using thin roof flashing aluminum but as soon as I tooled and installed the first blade I realized that was the wrong approach. 

The blade was too heavy. Tried foam, couldn't get the tooling and hot knife quite right. Finally just cut pieces from a 1 gallon water bottle, cut slots, slid onto and silicone to the fan blades then sprayed with anti corrosion silver paint

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