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Remove the top support beam from the rotor assembly and place it over the free ends of the
vertical supports, bearing on top.Hold or clamp in position and drill holes for large wood screws
through it and down into the vertical supports. Do not split the wood.
Remove the beam.
Raise the rotor into position. This is at least a two-man job.
Push the bottom shaft end piece down into its bearing, tapping gently if necessary.While the
rotor is being held up by hand, position the top beam.Slide the bearing down over the end piece
on the end of the pipe shaft, tapping gently with a mallet or heavy piece of wood.Screw the ends
of the beam down into the vertical supports.
If the bottom bearing support beam has been installed perfectly level, and the pipe shaft is
vertical at right angles to the beam, and the bottom bearing is properly aligned in its housing,
then the rotor should rotate smoothly in that bearing.
If there is any roughness in the rotation of the shaft end piece in the top bearing, you may try to
make further adjustments (in an adjustable bearing) in the alignment of this bearing. If that
doesn't do the job (or the bearing is not adjustable), you can try inserting shims between one end
or the other of the top beam and the top end of the vertical support until there is smooth
movement of the shaft in the bearing.
It is very important that the rotor turn freely. The bearings, especially the bottom one, could be
ruined, with consequent damage to the rotor and frame, if improper bearings and installation
procedure cause uncontrollable stresses and strains as the machine turns continually in the wind.
Take your time and be as resourceful as you can in these final steps.
It is possible that you may have to do something like the following:
*dismantle the rotor from the frame to make adjustments.
*plane down the wood surface of a beam under the bearing to adjust the bearing to the correct
angular relationship to the rotor shaft.
*go to a better bearing than one you were hoping would work.
Whatever you do now to get the rotor running smoothly will be worth the trouble you are thereby
going to avoid later.
You may find it easier to make the final assembly on the ground in a horizontal position and
raise it up after assembly by means of ropes.
At least half a dozen men are required for this final operation.
This is a three-stage rotor design that the author built in rural Zambia.By means of belts and a
bicycle wheel pulley mechanism it is geared to drive an automobile alternator or generator,
which generates electrical current that is stored in automobile batteries.