Fisher & Paykel Windmill Project (2007)

This project repurposed a Fisher & Paykel SmartDrive washing machine motor into a robust axial-flux windmill capable of off-grid power production. Built from recycled materials and tested through sun and storm, it still spins true to this day.

The PVC Blades

The Router and Blade Carver

A 4-meter long jig was created to replicate precise wooden blade profiles using a guided router sled. This would allow faster, more aerodynamic blade production for higher performance in moderate winds.

Blade carving jig — Full-length wooden blade carving machine using copy-trace method.

Wiring and Components

Internal wiring, stator rewinding, and battery regulation formed the electrical heart of the system. A 12–24 V rectifier allowed direct charging of off-grid batteries.

Assembled housing — Assembled steel unit — sealed and balanced for endurance.

Assembly and Bench Work

Robust steel components and welded housings were bench-assembled with attention to balance, weatherproofing, and structural endurance. The result: a windmill that survived months of Queensland's wild weather without a scratch.

Mill mounted to stump — Mounted unit on stump for early wind testing.

Windmill closeup — Rear view of hub and tail design.

Final Testing and Output

Once assembled, the windmill was tested under light wind conditions on a backyard stump. While elevation limited full output, early tests showed 100+ W of potential.

Credits & Further Reading

This windmill was inspired by community designs on thebackshed.com.
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