Trip to the local lyumberyard to find some nice clean cedar.
With most of the steel work finished I start to carve the blades by hand. I roughed out the basic shape with a Sawzall and cleaned up the blades with files, a wood plane and sanders. The blades are a complex shape so it takes time. I built a tall saw horse to make the job easier on the back. In hindsight it was well worth the time.
Painted and assembled.
The next part of the project I will build the alternator. A little machine is made to make the job of winding 10 coils easier.
My friend Scott helps out winding the coils. Makes the job so much easier if two guys rather than one wind. I built the winding machine low to the ground so we could sit while winding. I knew this would take a little time.
The coils are finished. The wire tie tails still need to be removed.
The coils are wired together and placed in a plywood mold for casting in polyester resin and fiberglass.