Test Tower Follies

Building a Test Tower...

What NOT to do...

This is a 30ft cedar pole that has been selected to be the test tower for my journey into the dynamic world of "Wind Power".

The pole is being supported by a pair of 12ft 2X4's as it makes it's assent to the heavens.

Above to the left I'm looking on in disgust as the pole decides to sway over and bend the 1/2" diameter rod that I had hoped would act as a hinging point. The affair is hardly a complete waste as both of the kids and wife were watching on, and all of us escaped injury.

The same tactic was tried a second time only to have the pole swing more violently in the other direction. At this point I dismissed everyone and opted to leave things for bit. Perhaps like the Tower of Babel I had set my ambitions too high, and angered a vengeful God...

Over 6 weeks have passed and Much has changed... After looking at a number of potential Tower options I found that I would never have been able to raise the pole as I'd originally tried.

Rather I'd have to have a minimum of 2 guy wires to keep it from swaying laterally side to side.

The tractor was employed as one guy point and a fence post for the other.

The cross member does make the test pole appear deeply symbolic from a Christian Icon perspective, but I hoped that it would be the mounting points for 2 wind mills.

After much putzing about and regretting that I'd hinted that God was vengeful, I was able to bolt the second rod through the base and assess the potential of the tower.

As I hate guy wires or any other support infrastructure that one could potentially walk, run or drive into, I began to really question if this was the kind of project that I'd envisioned.

After I slackened the guy wires I began to realize that yes, God was vengeful, and his full fury would rain down on me like the unclean infidel that I'm.

In actual fact my concern was that I was creating a "No-Walk-Zone" that extended in a circle the radius of the height of the pole for my family and friends that frequent the farm.

This coupled with the rather impractical nature of having to use an extension ladder to mount and dismount gear for testing made me acknowledge this as yet another classic "Frank Moment", the point at which I concede that I've made a significant mis-investment in time and energy. and like all mis-investments, by it's very nature little if anything can be recouped from the experience.

Once lowered to the ground I promptly took the chainsaw to the pole to insure that I would have a modest level of satisfaction in having accomplished something of value...

...kindling!

Curiously as I was wiping away my tears of despair and resigning myself to never harvesting the wind much above the level of a step ladder, I happened onto another idea that would prove both more utile, while enhancing the functionality of the tower structure as a test bed for the numerous generator designs that I'll execute in pursuit of the magic 1KW mark.

These 2 12ft pressure treated 4X4's cost $30 CDN, and will be the heart of the structure.

This is the basic structure assembled on the ground as all of the hardware is carefully fitted to ensure that all goes well.

One beam was cut in half and the other is mounted 3 1/2ft down between the 2 supports.

The 1/2ton winch was originally destined for the hunt camp to aid in swinging all that venison up the meat-pole, but that will have to wait.

Now this is where I'd hoped that I would have been earlier in the summer.

This is very safe, easy, and stable to the point that I would encourage the kids to play within any distance of the structure.

Once raised, a second length of rod bolts the cantilevered beam upright.

The beam is raised in seconds with the winch assembly and secured just as fast.

Not really visible is an eight inch wide plank that is bolted just above the winch to act as a stop for the beam as it reaches the vertical position.

Although I may not have hit the height that the original configuration offered, I still have at least 15ft, and the site is on the top of a hill.

The open field below the tower, extends for several hundred meters and is bordered on either side by mature forest. This creates a funnel effect for the wind to sweep straight up to the tower.

This assembly will be welded and mounted onto the main beam.

As the current set of generators are rather small I have no concerns about mounting 2 side by each.

The center pole is 9ft long and will extend at least another 6 ft above the top of the main beam, yielding a total of 20ft plus for the total height of the windmills.

The heavy pipe has 3 mounting holes drilled that will be secured by 3/8th" threaded rod.

This is the gratuitous "Weld Shot" that features so prominently in every DIY web-site.

There is something base and primal in welding metal, even if they are thick slathering welds, I just want to get drunk and pick a fight with someone I know I can kick the shit out of...

But as usual I repress these urges and simply quench my thirst with a limited qty of beer and rough house the dog until he won't play any more...

And so another chapter draws to a close with at least something of minor significance to show for my efforts.

The 2 mills that are to be mounted have been in the shop for over a month as I periodically pick at them with mild disinterest. But with a reasonable structure to mount them on now complete, I have a renewed ambition to finish them off.

The Steel pipe extension seems to be just a little too much and will be cut back to about 2ft above the top of the beam. as it introduces a significant loading effect on the main beam when raising it (even without the mills).

With a functional structure in place and integrating a system that allows for easy swapping and maintenance of the generators, I hope to be closer to the goal of building my own generators this fall.

Support theworkshop.ca

Back to Energy