Step 3: The Blades
Rather than spending hundreds of dollars on blades for my wind turbine, I made my own blades out of scrap PVC I had lying around. Everyone out there tells you to use 8″ PVC for wind turbine blades, and let me tell you, it works far better than the 6″ I was able to get. I had to get creative to make the 6″ PVC work (less curvature than 8″).
I started by cutting down my PVC pipe. The rectangles I made are 5.5″ by 24″. I then cut these down to triangles where the short end is 1.25″ wide. After that, I cut out a triangle on the end where it will attach to the generator hub. I clamped the blades in a vice when I cut this and drilled the holes so they would all be about the same.
Use scrap 90 degree angle iron when marking to cut; you will get a straight line that way.
You can use a hacksaw, but I would recommend a reciprocating saw.
Use saw blades meant for steel (fine tooth).