Ronald Headley on June 20th, 2016

18 Foot Aluminum Windmill

18 Foot aluminum Windmill

22 Foor Aluminum Windmill

22 Foot Aluminum Windmill

30 Foot Aluminum Windmill

30 Foot Aluminum Windmill

Are you considering one of the large decorative aluminum windmills?  Here are some things to know.

  • Made in USA – Amish Handcrafted
  • Aluminum with stainless steel nuts, bolts and fittings, heavy duty vinyl trim
  • Will not rust -Never need painting
  • Unique ground anchor system – no cement needed
  • Wheel and tail designed so that in high winds the wheel will not over-speed
  • Can be erected and set without the use of a crane of other special construction equipment

Read the rest of this entry »

Ronald Headley on June 20th, 2016

Your 22 foot aluminum windmill will be delivered by a common carrier (semi truck)  typically the shipping company or the driver will phone you prior to delivery to verify your address and make certain someone is there to unload the truck.  The truck driver will move the two boxes to the back of the truck.  You are expected to offload the two boxes. Read the rest of this entry »

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Ronald Headley on June 20th, 2016

The legs and braces are all in the long box.  Begin by opening that box and removing the wrapped bundle of legs and braces

Legs Bundle

Legs Bundle

Separate out the 8 legs tubes – and lay out and sort the braces and cross pieces – the square box that the wheel and tail came in works well

braces and cross braces Read the rest of this entry »

Ronald Headley on June 20th, 2016

Assembling the first tower side

NOTE AT THIS POINT YOU WILL NEED TO CHOOSE IF YOU WANT THE NUTS ON THE INSIDE OF THE TOWER OR ON ON THE OUTSIDE

Either way will work fine – it may be easier to put the bolts through from the inside and place the braces and cross bars on and then place the nut – doing it this way put the nut on the outside of the tower.

The direction sheet that comes with the windmill says to put the bolt through the braces and cross braces and through the leg and then put the nut on.  This way puts the not on the inside of the windmill frame.  In this series or photos the nuts are on the outside of the frame – again either way is fine – choose one way and do the entire windmill that way.  I will give the directions the same way as is on the manufacturers instruction sheet. Read the rest of this entry »

Ronald Headley on June 20th, 2016

Continuing with the tower assembly

Lay the remaining two legs on the ground and assemble a second side of the tower exactly like you assembled the first side (see part 3)

22ft Windmill TowerLay the second side of the assembled tower on top of the first assembled side

Put the tower top (mast head) with four 1 3/4 bolts – the legs go inside of the tower top.  Place a bolt through the tower top and then through one leg (top of the leg where there is one hole) and add a nut and finger tighten the nut.  Continue with each of the other three legs.

At this point it may be helpful to set the tower top on some sort of support such as a saw horse and held there with a bungee cord.

It takes two people to do this next step one on each side of the lower end of the tower

Locate the remaining two 54 inch Square tubes and the remaining 4 of the 72 1/2 inch cross bars – each person will have one 54 inch Square tube and 2 72 1/2 inch cross bars and two 2 1/2 bolts.

The two assembled halves of the tower should at this point be laying on top of each other and the tower top should be loosely attached to the top of the tower – the top of the tower can be either on the ground or on a saw horse or other support (be sure to bungee cord the top of the tower in place if you have it up on a saw horse or other support)

Each person puts a 2 1/2 inch bolt through one of the 54 inch Square tubes and through each of two of the 72 1/2 inch braces and through the holes in the BOTTOM tower half and adds a hand tightened nut.

Each person now lifts up their side of the upper tower half and the 54 inch Square tube on their side.  Each person places a 2 1/2 inch bolt through the 54 in Square tube and through a 72 1/2 inch cross bar and then through the holes in the legs of the TOP half of the tower.

Each of the two people at this point can assemble their side with the angle bars and cross pieces from each side maintaining the way the top and bottom halves are assembled

Or the partially assembled tower can be gently rolled so that one of the sides to be assembled is now on top and then add the angle bars and cross pieces to the side. Once completed the tower can be gently rolled so that the final side is now on top and then the angle bars and cross bars can be added

22 Foot Aluminum Windmill

Mount the Stabilizer Plate with the bearing toward the top with four 1 1/2 inch bolts (step 5 on the manufacturers instruction sheet)

Mount the two tower platforms pieces that have 4 holes to opposite sides – use 1 3/4 inch bolts – place the bolt through the platform piece then through the 28 3/4 inch cross bar and through the leg and add a hand tightened nut

Finally add the two platform pieces that have two hole on top (toward the top) of the attached platform pieces – Use 4 of the !/2 half inch bolts – put them through the top pieces then through the bottom pieces that are attached to the tower and add two hand tightened nuts (step 6 on  the manufacturers instruction sheet)

22 foot aluminum windmill tower

 

 

Ronald Headley on June 20th, 2016

Study part 7 of the manufacturers instruction sheet.

The next step is to carefully stand the tower up.  Use four people to do this.  Two at the bottom at each side and two starting at the top begin to lift the tower up like you would do with an extension ladder.   Stand the windmill up on level ground and measure diagonally across the make certain the tower is square.

Once the tower is square then tighten all of the bolts on the bottom row of tube braces, and then tighten all of the nuts on the next row up.

NOTE:  When tightening the bolts do not over tighten.  When the nut or the bolt head (depending on which way you decided to place the bolts) start to dimple the tubes of the legs this is tight enough.

After you have each side of the bottom two braces tight carefully lay the tower back down.

Start at the top  and tighten all of the bolts – turn the tower and tighten the bolts and work all the way down to the bottom.

22 foot aluminum windmill tower 22 Foot Aluminum Windmill

Once everything is tight check to make certain all the bolts have been tightened

Place the 4 anchor pads onto the Splicers on the bottom of the windmill – use four 1 1/2 inch bolts for the anchor pads – finger tighten these bolts for now.

Ronald Headley on June 20th, 2016

The large windmills have anchor pads attached to an aluminum tube that slides into the bass of the windmill tower and is held by one bolt.  It is recommended that cement not be used.   Just dig out four holes (a power post hole digger is a huge help here – but also be prepared to enlarge and shape the post holes)

On the 18 and 22 foot windmills the anchors extend 30 inches from the base of the tower and on the 30 foot windmill the anchors extend 32 inches from the base of the tower.  The holes need to be a few inches deeper than the anchors to allow for some crushed rock or gravel to be placed at the bottom of the hole.  The gravel allows moisture to drain.

The steps are:

  1. Layout where the holes need to be dug
  2. Dig the holes
  3.  Attach the anchors to the tower and stand the tower up
  4. Lift the tower and drop the anchors into the holes
    1. make certain the anchors will go into the holes and that the holes are a few inches deeper than the anchors
    2. there will probably need to be adjustments made to the holes – the anchors are a continuation of the angle of the tower so the holes will need to allow the anchors to angle out.  In the next post there is more detail as well as a sketch
  5. Lift the tower out of the holes – add some gravel or crushed rock to the bottom of each hole and add some sand on top of the gravel
  6. Set the tower back into the holes with the anchor pads resting on the sand
    1. Adjusting the amount of sand in each hole is how to get the windmill tower lever
    2. Make certain the tower is level – a level placed on the lowest horizontal angle braces will show level – check all four sides
    3. Adjust the sand until all four sides are level
  7. Lift the tower back out of the holes and tip it down to where the top wheel, pivot and tail can be mounted to the tower
    1. Be sure to lock the set screws in the thrust bearings at this time – the pivot braces should be held above the top of the top thrust bearing and the shaft should extend all the way through the lower stabilizer thrust bearing.
  8. Set the tower back up so it is resting on the anchor pads and lift it over and into the holes placing the anchor pads back on the sand
  9. Check again to make certain the tower is level on all four sides
  10. Back fill some dirt (a few inches) into the hole and tamp the dirt down
  11. Check to see that the tower has remained level
  12. Continue to back fill the holes a few inches at a time and continue to tamp down the dirt until the back-fill is level with the surrounding ground

IMG_1782

Ronald Headley on June 20th, 2016

Locating where to dig the holes for the windmill.

  • The 18 Foot Windmill has a 54 X 54 Inch Base – The anchors extend 30 inches below the tower base
  • The 22 Foot Windmill has a 72 X 72 Inch Base – The anchors extend 30 inches below the tower base
  • The 30 Foot Windmill has a 84 X 84 Inch Base – The anchors extend 32 inches below the tower base

Because the anchors continue the angle of the tower legs the holes need to be dug outside of where the base will be – if using a power post hole digger the center of the hole will set so the closest hole edge is at the corner of the tower base – in the drawing below the square represents the windmill base and the circle show how the holes are dug outside the the corners of the windmill base

Hole

Ronald Headley on June 20th, 2016

In the drawing below is shown how the anchors continue the angle of the tower – the holes are dug so the tower can be dropped into the holes.

Dig the holes a few inches deeper than is needed for the anchors and add some gravel or crushed rock to the holes and then add some sand

Lift the tower and allow the anchors to drop down into the holes – the sand is used to level the tower.   Once level remove the tower – tip it down and add the top and set the vertical shaft into the thrust bearings and lock the shaft with the set screws in the trust bearings

Set the tower with the top in place back up and again drop the tower with the anchors into the holes – check all four side for level and begin to back fill

MountAnchorsHere the tower is being lowered into the holes checking to see that the anchors will drop down into the holes

IMG_1772

Here the top has been added – the windmill has been set in the hole – adjustments to the sand has been done to make certain the completed windmill is level

IMG_1776

Ronald Headley on June 20th, 2016

Here are some photos of the completed 22 Foot windmill

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