This project goes over the build of a Homemade rope making machine using a simple cordless power drill and some inexpensive materials that are sourced from the local hardware store. Here are the materials needed for this project:
Three quarter inch by five inch eye bolts with hex nuts
Plastic Castor Wheels
two by two and one by six by six piece of lumber
Old bicycle tire tubes
Take the board and cut it to length of seven and a half inches and took the first piece and doubled it over the second one and cut them together so that they are exactly the same length. Then I took a piece of two by two and cut it eight and a half inches long.
Take large fender washers and position them on the board forming a triangle, you want to do it in such a way so when you add your two by two to the top as well as the bottom, it has similar spacing at the top and the bottom. Put the two boards together, mark the centers and drill the holes.
Next step is to build the metal spinning hooks. These spinning hooks are going to be made out of eyebolts which is used as a hook to put the strings on. We take 3 plastic castor wheels and use them as a pulley , connect them together with a small piece of bicycle tire tube so that when one is spun ,all three of them would spin together.
We take the 3 eyebolts and push it through the hole and secure them tight with a small cut washer and hex nut. It is locked in place but should spin freely. Put with wheels through the bolts and secure them using fender washers, cut washers and nuts.
Take an old used tire tube piece and line it up between the two washers and cut up a piece that is roughly about the same distance as that gap. We loop the tube over the pulley all at once.The Second board is pushed through the bolts over the wheel pulleys.Make sure everything is lined up symmetrically. When we turn one bolt, the belt drives the other two pulleys and they all spin together.
As we are running the hook spinner, we are going to need something to hold it at the other end, To make the other end of the mechanism that holds the strings in place, we take six inch piece of common board and eight and a half inches of our two by twos on the bottom to secure it as a base and them we clamp it over a table.
The idea is that as each hook begins to spin, the two cords attached to it will intertwine with each other. And then eventually all three of those cords will mesh together to make a nice three stranded rope.
As the strands are twisted, it creates tension on the backboard. To relieve the tension, we drill a hole through the backboard and tie the rope to another counterweight rope through a swivel hook that pulls the tension and allows it to rise as the cord is pulled.
We also make a rope makers top that will help guide those strands into the beautiful three strand cord. We add two ropes between the spinner mechanism as guidelines and connect it to the back board to accommodate the rope makers top. The idea is that as the tension builds it will glide forward and guide the individual strands into place to form a three stranded rope.
We sandpaper the holes on the rope makers top to make it smoother so that the lines won’t snag up when they start twisting. We put a wooden knob on the back to reduce the friction so that the rope makers top can slide smoothly.
Loop the cords through each of the three hooks on our rope maker machine .Form a slipknot and connect it to the swivel hook. We have our rope machine build complete .
To tie and cut of the rope, take a small piece of electrical tape and wrap it around the end where you want to cut it off. Cut The Rope at the back just where the electrical tape ends .
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- How to Install a Complete Micro Hydro Alternative Free Power Generation System for your Home.This project goes over the details on how you can setup and install a 300W Off the grid Micro Hydro System for your home . The water source mentioned in this project have a flow rate of 15 - 30 gallons a minute and the drop between the source and the house is about 150 feet. The first step is to make an intake angled screen box for the system that helps in channeling the water from the source. The aluminum screen on the top blocks leaves, sticks and other debris to pass through into the box . The box is made of a 24 inch 2X10 ,2X4 and an 2X8 angled piece treated lumber. We add 3 one and quarter inch attachment points on the lower side of the box for the hdpe poly pipes. The box is secured using exterior screws on the outside and inner tubes on the seam to prevent leaks. The box is installed on the creek with help of couple of three and half inch concrete anchors and two boards are screwed on both the sides for support. The outlet poly pipes from the intake screen box goes to 55 gallon plastic barrel which acts as a silt catchment and also an air free source. The 3 outlet pipes are connected to the top of the barrel with the help of uniseal rubber gaskets. A 2 inch pipe is installed midway on the tank for the penstock. We also install an overflow pipe near the top of the tank to take the extra water out and a three inch cleanout pipe at the bottom . The cleanout pipe can be unscrewed to remove the silt and debris out. To take the water from the intake to the turbine, the penstock used here is a 100PSI 1100ft 2 inch poly pipe. A threaded adapter is glued to the outlet coming out of the barrel. It is then connected to a two inch full port shutoff ball valve followed by an another threaded adapter and a pipe. The penstock poly pipe is attached to this pipe using barb fittings with hose clamps. Next step is to install the pressure gauge and the surge tank to our penstock pipe. Water will come down through the poly pipe into another PVC pipe fitted with a pressure gauge, surge tank, two inch closing ball valve and a union to remove the turbine from the pipe. The surge tank is made of a standpipe that will prevent any water hammer affecting the pipes. The two inch poly pipe coming out from the barrel is connected to the two inch PVC surge tank and pressure gauge using regular . If the main shut off valve is suddenly closed, this tank will allow some of the surge to be absorbed. Next step is to build a housing for the micro hydro turbine. It is going to have a lid that opens up and a drain field pipe that goes out back to the creek. The housing for the turbine is made of three quarter inch plywood that is 2 X 2 foot wide and one foot tall. The turbine sits inside the hosing in the middle with the help of some 2x 4 scrap wood and a bucket lid piece. Then a 3 inch exit pipe comes out of here down through the middle of the housing .This drain pipe keeps the water from piling up under the turbine. The Micro Hydro Turgo Turbine is custom built based on the head pressure and the flow rate of the water source. It has three ball valves and four quarter inch jet nozzles coming out of them. The ball valves can be separately turned off when there is not enough water .The turbine is wired up to be three phase. The water coming out of the penstock hits jet nozzles that turns the Pelton wheel which is connected to 3 phase AC motor. To connect the turbine to our house, we use a 10/3 underground feeder wire. The wire is enclosed in a one inch conduit pipe. The proper way to install wire into a conduit is to get your conduit all glued together. And then you have a vacuum that pulls a string through. You tie your string to the wire and then pull the wire through the conduit. The wire goes into the house through a PVC conduit body. We install a junction box on the housing of the turbine to join the 3 phase turbine output wires to the 10/3 UG feeder wires coming from the house. Inside the house, we connect a rectifier to the three legs of the three phase coming from the turbine .This converts the AC generated into DC power. To generate useable power from this micro hydro system we need to install certain electrical devices in our houses. These include the MPPT Charge Controller, Grid Tie limiter Inverter, breaker box, disconnect switches and the batteries. These components are mounted on a 2 X 2 foot ,three inch plywood board. In case there is some excess heat for one of these electronics at some point, we cover the plywood board with a piece of sheet metal so that it will act as a heat sink. From the rectifier, the connection goes into a 25amp breaker box .The red wire goes into the breaker box and then further connects to positive of the charge controller. The negative white wire is directly connected to the negative of the charge controller. The five 12V AGM batteries are connected in series using four gauge cables. The positives from the batteries are connected to the charge controller and the inverter via DC switches .These switches allows us to isolate and disconnect the components individually. The negatives from the batteries are connected to the negatives of both charge controller and inverter respectively. The inverter is further connected to receptacle from where it goes straight to the main supply. https://www.youtube.com/playlist?list=PLTrfbWw_mKRL5Ae_x1Q4-1pOs0NJGwnzi