Heres a simple way to make a prop, it might not be the best design in the world but these start easy and with some easy improvements to the shape of the blades its possible to get them to spin faster but for now i will show how to put one together in a couple of hours.

Heres the start its a car radiator fan blade of a vw audi and theres plenty about in scrap yards.These fans come with different numbers of blades on them and this one has got 3 blades.The general rule of thumb is the fewer blades the faster it will spin as a wind genny prop. You can see the twist on the end view of the blade.

Now i need a donar to make the blades and what better than a drum or bucket that has already got a curved shape to it. For this prop i chose a large drum that holds 205 litres of car shamphoo.First i cut the top off the drum.Using the fan i hold it against the top of the drum and draw 2 lines lines either side of one of the blades as to give the width at the root ( bottom of the blade ).

Due to were i live and big wind gennys dont go down too well here i cut out a strip about 22 inches long.I wanted to try a prop 4 foot in diameter and 22 inches long blades is plenty when the hub ( the car fan ) is taken into account.

Theres the first blade and after some trimming to shape it i used it as a template to make 2 more blades from the drum.

Each blade is mounted to the fan using 3x3.2mm pop rivets and a nut and bolt with washers for extra security.The blades are mounted to SCOOP side of the fan blades this is important.

There it is a 4ft prop on the wind genny.I felt this was way too heavey and big for the town genny and took it of, it did start very easy in under 10mph wind but i think this one shall be kept for a bigger stronger genny.To be continued.......

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