WINDMILL ASSEMBLY CONSTRUCTION MANUAL

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TOOLS AND MATERIALS FOR CONSTRUCTING A WATER PUMP

Tools:A. HammerB. SawC. Wire Cutter / PliersD. Hacksaw (or angle grinder)E. Welder (arc welding machine)F. Measuring TapeG. Scissors

MATERIALS FOR HAND OPERATION (UP TO 1 ACRE):

H. 13” Tire!. 4 meters Y-10 (10mm Re-Bar)J. Shock - Piston or Smooth Round Bar for AxleK. 75mm NailsL. 100mm NailsM. (1) 150mm NailN. (2) BearingsO. Garden Hose 25mm diameter, 32cm longP. Rope (Nylon)Q. 40mm PVC with 2 BendsR. 5L Water or Oil Jug Empty (Funnel)S. 20L Jug / Jerry CanT. Binding WireU. Trees / Timber for FrameV. 75mm Pipe Outlet

ADDITIONAL MATERIALS FOR WIND OP-ERATION (MORE THAN 1 ACRE):

W. Blue Gum Tree TrunkX. BambooY. Grain SacksZ. Large Tin Can

*Not all tools and materials are shown in diagrams

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HAND CRANK INSTRUCTIONS

STEP 1 PIPE ASSEMBLYMATERIALS: (2)6m lengths of 40mm PVC, (2) 40mm PVC bends, (1)96cm length of 40mm PVCTOOLS: Hacksaw, Hammer. (1)150mm Nail

1. Connect each 6m pipe to a bend.2. Use 96cm length of 40mm PVC to connect the bends to each other.3. Punch holes in this connection piece using the hammer and nail.4. Put the pipe “U” into the well so that it is a minimum of 60cm below the water line in the dry season.5. Decide where you will be standing to hand operate the pump.6. Using the hacksaw, cut the top ends of the pipe to be 45cm below the crank location.7. Remove the pipe from the water and lay it on the ground.8. Using the hose, determine how many hose lengths the pipe is; this number tells you how many plastic circle washers you need.

STEP 2 ROPE ASSEMBLYMATERIALS: Rope, 5L Jug, 20L CanTOOLS: Scissors, 1 Nail, Hammer

1. Using scissors, cut circles (35mm in diameter) from the side part of the 20L can.2. Punch a hole in to each circle (washer) with the nail.3. Take the rope and beginning at one end and tie a knot.4. From the other end, thread a plastic circle washer onto the rope and push down to rest on the knot.

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Then tie another knot to loosley hold the washer in place.5. Repeat Step 4 until all of the washers hve been threaded. every 32cm-48cm the entire length of the “U”.6. Put the rope into the pipe.Step 2 Rope Assembly (Continued)7. Put the 5L jug on the pipe.8. Put the 20L can on the outlet.

STEP 3 PULLEY ASSEMBLYMATERIALS: Tire, 75mm Nails, Y-10 (10mm re-bar), Shock, Bearings, 32 cm of HoseTOOLS: Welder, Hammer

1. Cut tread off the tire.2. Nail tire together on bead.3. Cut Y-10 to size.4. Weld Y-10 frame.5. Fasten frame on tire.6. Weld shock axel in frame

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HAND CRANK INSTRUCTIONS (CONTINUED)

STEP 4 FRAME ASSEMBLYMATERIALS: Wood, NailsTOOLS: Saw, Hammer, Measuring Tape, Shovel

1. Measure the height where pulley will be located and add 300mm.2. Cut wood supports to length.3. Measure width of pulley (bearing to bearing - this determines your frame width).4. Put wood supports in ground (300mm deep minimum).5. Cut and secure cross pieces.6. Add additional support where necessary so that frame is sturdy.

STEP 5 FINAL ASSEMBLYMATERIALS: 5L Jug, 20L Can, Wire, Wood, 75mm PipeTOOLS: Scissors, Nail

1. Put “U” pipe in water and secure to wood posts with wire. (Use nail to twist wire together securely but do not crush or impact PVC pipe by tightening too much).2. Cut side off 20L can (same side as in Step 2 item).3. Use the 40mm pipe diameter for size and cut a hole in the opposite side of 20L can.4. Place the can on the outlet pipe (Step 2, item 8).5. Put the 5L jug on inlet to act as a funnel for the rope (Step 2, item 7).6. Wrap the rope around the pulley and tie it together end to end. (Knot must be secure but small enough to fit through 40mm pipe).7. Secure 75mm pipe to 20L can. This pipe will take the water from the pump to your irrigation canal.8. Test pump.

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TROUBLE SHOOTING: *If rope is slipping, tie it tighter.*If rope is catching on inlet, adjust the angle of funnel.*If air comes out with the water, punch more holes in connection piece.*For deeper wells, reduce the diameter of the pipe going into the water.

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STEP 4

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WIND OPERATED WATER PUMP [WINDMILL] INSTRUCTIONS

The following instructions and diagrams are to help you construct a vertical axis windmill to operate a rope and washer pump. Since the construction is primarily of bamboo, you will need to add diagonal supports wherever necessary to prevent excessive flexing of the bamboo. To join the bamboo use binding wire twisted tighly using a small lever (150mm nail). Where the stronger joint is required, drill holes in the bamboo and pass the wire through.

1. Cut center post (blue gum eucalyptus or similar) to 4.7m long.2. Construct box frame out of bamboo (3.5m x 35cm x 35cm)3. Construct windmill frame (See Diagram 1). a. (Top cross #1) Attach 3m bamboo across the top of the box frame. b. (Vertical supports #1 & #2) Attach 3m bamboo down from each end of the top cross. *There should now be two 3m x 1.5m rectangles either side of the box frame. c. (Bottom cross #1 & #2) Attach 1.5m bamboo from bottom of each vertical supports to box frame. d. (Top cross #2) Attach another 3m bamboo across the top of the box frame, perpendicular to the first top cross. e. (Vertical supports #3 & #4) Attach 3m bamboo down from each end of the top cross #2. f. (Bottom cross #3 & 4) Attach 1.5m bamboo from bottom of vertical support #3 & #4 to box frame. *There are now four 3m x 1.5m rectangular frames on four sides of box frame. g. (Main diagonal supports) Attach bamboo from inside bottom to corner of each rectangular frame to the outside top corner. h. Attach outside square supports from each outside corner of the windmill frame to the adjacent corner (on both top and bottom corners). This forms two squares; one at the top and one at the bottom of the windmill frame.4. Construct wind-panel (see Diagram 5) a. (Long side) Cut 3.2m bamboo. b. (Bottom side) Attach 1m bamboo 25cm from bottom of 3.2m bamboo. c. (Top side) Attach 1m bamboo 45cm from top of 3.2m bamboo. d. (Short-side) Attach 2.5m bamboo at ends of top and bottom sides to form 2.5m x 1m rectangle. e. (Wind surface) Weave 4 grain sacks (1m x 0.6m) together at long sides to form a 1m x 2.4m rectangle. * Repeat steps a.-e. four times to make 4 wind-panels.

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T O P B E A R I N G T O P C R O S S B A M B O O

B O T T O M C R O S SB A M B O O

P A N E L S H O U L D B E 1 M W I D E

P A N E L S H O U L D B E 3 . 2 M L O N G

C O G C E N T E R P O S T

B O X F R A M E

B O T T O M P I V O T

V E R I C A L S U P P O R T B A M B O O

R E M O V A B L EW I N DP A N E L

T O P P I V O T

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WIND OPERATED WATER PUMP [WINDMILL]INSTRUCTIONS (CONTINUED)

5. Make panel pivot points (Diagrams 1 & 2) a. (Bottom corner holder) Close bottom end of 12cm long x 40mm diameter pipe (or hollow bamboo). b. (Panel pivot point) Attach bottom corner holders at the outside bottom of the windmill frame. c. (Top corner holder) Attach a short (approx. 15cm) bamboo across the corner formed by the tp cross bamboo and the outside square support to form an equilateral triangle 10cm x 10 cm x 10cm. To rotate counter-clockwise attach all top corner holders in the left of the top cross. To rotate clockwise, attach all top corner holders to the right of the top cross. *Do not mix left and right; all top corner holders must be on the same side of the top cross.

6. Install top bearing a. Make a support out of bamboo to hold the bearing inside of the box frame. This support should be 1m from the top. b. Attach the bearing to the center of the bearing support inside the box frame. c. Counter sink bearing into center post. Different types of bearings may be used: wheel, bicycle, thrust bearing, etc. *Modify support as needed.7. Sink center post 1.0m into ground. Secure with concrete if available. Treat post for termites if possible. The post should rise 3.7m above ground.

T O P C R O S S

A D D I T I O N A LB A M B O O S E G M E N T

W I N D P A N E LP I V O T P O I N TB O T T O M C O R N E RH O L D E R

V E R T I C A L S U P P O R T

T O P R A I L O FW I N D P A N E L

DIAGRAM 1 DIAGRAM 2

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8. Lift windmill frame onto post and secure bearing to center post. (In some cases you may secure the windmill frame to the post prior to setting post in the ground. You would then lift post and frame into place together.)9. Install wind-panels by lifting long side through the top corner holder and lowering down into the bottom corner holder. All panels should open the same direction: clockwise or counter-clockwise. *When closed, wind-panels should rest against the main diagonal support bamboo on the windmill frame.10. Tie rope from outside edge of wind-panel to preceding vertical support bamboo such that the wind-panel can only open approximately 90 degrees. *Adjust the angle to improve performance and stability. 11. Construct cog (Diagram 3): a. Cut 8 pieces of bamboo to 1.2m. Split each piece to form 16 pieces of 1.2m split bamboo. b. Attach 2 pieces of split bamboo to bottom of the box frame and windmill frame such that they cross 60cm from the center post and are approximately 35cm from bottom of the windmill frame. c. Make 8 of these crossed, split bamboo evenly spaced around the center post. This forms 8 cogs, 120cm in diameter (60cm from center post). 12. Attach Rope and Washer pump: a. Extend rope with washers around the windmill cogs such that the rope is pulled in the appropriate direction. b. Install a pulley to guide the rope into the intake pipe of the water pump. Use a large tin can for the pulley.

B O T T O M P I V O T( D I A G R A M 1 )

C O G S H O U L D B E 6 0 C M F R O M C E N T E R P O S T

DIAGRAM 3

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SOLAR WATER PASTEURIZER INSTRUCTIONS

1. Start by screwing together the 250mm long 25x25 mm and the 860mm long 25x25 mm to form a rectangular frame.2. Lay the first pane of glass on a flat surface. Find a place that it can sit, stay dry, and not be bothered for at least 4 hours. 3. Apply a large bead of silicone around the center of 1 side of the wooden frame.4. Lay and gently press the frame and silicone bead onto the glass pane.5. Next apply a secondary bead of silicone around the inner gap between the wood and the glass. Smooth the silicone with your finger to insure that there are no cracks or leaks.6. Allow the silicone to dry. Check package for the appropriate dry times.7. Once dry, add a large bead of silicone on the top of the wood frame.8. Place the 2nd glass pane on top of the frame and press gently.9. Allow the silicone to dry.10. Once dry, reseal the outer seam edges of the glass and check for any possible leaking areas. Once all of the seams and joints are sealed allow the silicone to dry.11. Next drill a 20 mm hole on a side of your choice. This will be your fill hole.12. On the opposing side of the fill hole, on the bottom side of the system, drill a second 20 mm hole for your drain valve.13. Insert the 20 mm hose and seal with silicone.14. Once the silicone is dry, attach your valve of choice.15. Finally attach the piece of sheet metal to the back of the glass pane using a silicone bead.

TO USE:

1. Fill the system with water.2. Face the system so that the angle of the front glass is directly facing the location of peak sun.3. Wait for water to boil, drain, and let cool before drinking.S

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V A L V E

G L A S S

W O O DF R A M E

F I L L H E R E

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CHANGE A LIFE.FIND OUT HOW.

For more information,contact John Drake:

2869 Carew Ave.Winter Park, FL 32789johndrake@africawindmill.org(407) 432-0795

or visit our website:

AFRICAWINDMILL.ORG

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AFRICAWINDMILL.ORG