Wind Vane

The following project is a wind vane with a custom designed propeller.

Created as a functional garden decoration.

3D printing filament PLA

M3 x 6mm screws - Qty 2

M3 x 20mm screw

M3 washers - Qty 2

M3 x 5 + 6mm threaded hex standoff.

Metal tube 6mm (dia) x 21.6(L) metal tube (Straw)

Brass tube 3.5(dia) mm

May prove more cost effective to buy a range of values rather than individual values unless you already have them available. Some components may also have a MOL greater than the quantity specified in the component list.

Tools

3D Printer

Saw

Needle files

Sanding paper

Craft knife

Screwdriver

Marker

Awl

Drill

Drill bit 2mm

Drill bit 3mm

Drill bit 5mm

Drill bit 6mm

Reamer

Plastic Adhesive

Epoxy putty

Varnish/thread lock

Silicone Lubricant

Know your tools and follow the recommended operational procedures and be sure to wear the appropriate PPE.

The 3D printed elements were designed using BlocksCAD, sliced using Cura 4.5.0 and printed on a Labists ET4.

1: Propeller, Size:125(dia) x 17.6(H) mm, Weight: 32g

2: Swing Support, Size:10(W) x 20(H) x 30(L) mm, Weight: 3g

3: Vanetail: Size: 128.6 x 113.1 x 3(H) mm, Weight: 25g

4: Vane Clamp: Size: 16(dia) x 47.4(H) mm, Weight: 9g

Print details:

Layer Height: 0.15mm

Infill Density: 100%

Shell, Wall thickness 2mm

Build Adhesion: Skirt

No supports required.

Although, printed using PLA which subject to composition and the environmental effects will last a number of seasons but for long term use PETG or some other material better suited to the extremes of external environmental conditions are an option.

Some post processing may be required to remove aberrations in the cavities and around the edges with sanding paper and needle files in addition to opening and smoothing the holes with a drill bit.

Use a needle file and/or sanding paper to smooth the parts in areas were they come together.

Prepare the propeller.

Open the hole with a 3.5mm drill bit.

Cut a 12mm length of 3.5mm brass tubing, smooth the inner and outer edges with a file/sanding paper.

Insert into the tube a flat headed nail or screw and using a vice or G clamp press the tube into the centre of the propeller until fully inserted.

Prepare the metal tube for the propeller.

If necessary with a reamer or 5mm drill bit open out the end on the tube to accept the standoff.

Apply a suitable adhesive or epoxy putty into the end of the tube and push in the standoff.until its flush with the end and set aside to cure.

Prepare the vane tail.

Apply a little adhesive to the edges of the vane tail to which the vane clamp will be attached.

Push the vane clamp onto the vane tail, if necessary insert the metal tube unto the hole in the tail clamp to retain alignment. Be aware of applying too much adhesive if you wish to remove the tube at a later time.

Set the vane tail assembly aside until the adhesive has cured.

Prepare the swing support.

Open the holes in the swing support with a 2mm drill bit

Align the 2 x M3 x 6mm in the holes in the swing support and with firm pressure screw them into the holes ensuring they sit straight in the holes.

Push the tube into the vane tail, if not already done so in the previous step.

Slide the swing support box section onto the tube.

Insert the M3 x 20mm screw through the hole in the centre of the propeller.

Fit the two washers over the end of the screw and insert the screw once having applied a little varnish or thread lock into the end open end of the standoff and tighten

To improve the spin, stability and smooth rotation it helps to balance the wind vane.

Attempt to balance the wind vane by placing the open end of the cylinder on the tip of your finger and slide the tube forward and backwards in the swing support as required.

Once balanced tighten the screws to lock the swing support in place ensuring the vane tail is vertically aligned.

Insert another 6mm tube into the open cylinder of the swing support, this should be a tight fit but apply a little adhesive if necessary.

Attach a tube, rod, nail or skewer to a suitable pole onto which the 6mm tube will sit and spin freely.

Silicone lubricant can be applied to the moving parts to ensure smooth running.

All you need now is a windy day for the full effect.