Kinetic Windmill Sculpture

Materials:

wire feed welder
angle head grinders
metal cutting band saw
propane fired forge
plasma cutter
hammer and anvils
drill press
bench grinder
hydraulic press
sheet metal shear and brake
bicycle
24-gauge hot rolled steel sheet metal
stainless steel sheet metal: recycled restaurant counters
24-gauge recycled scrap copper
paint
pop rivets
1/2" steel pipe
5/16 diameter steel rod
1/2" diameter x 1" bolt with nut
degreaser cleaner
wire brush
welding gloves
respirator
welding shield
welding safety glasses
tongs
pliers
leather coat
spray primer
flat black spray paint
red spray paint
muriatic acid*
water
hydrogen peroxide
*Muriatic acid is a hazardous chemical.

1. Disassemble a three-piece crank assembly bicycle (figure A).

• Cut cables, chain and remove the left pedal.
• Save the chain ring and crank. This will become the propeller hub. Save the round tapered lock pin with the flat side washer and nut.
• Cut and remove the pedal from the sprocket 1-inch above the lock pin.

Crank assembly: (This is the part of the bike with the pedals and chain.)
• Cut large pipes 1 inch up from the lugs and cut small pipes 1/2 inch from the lug (figure B).

Headset Assembly:
• Remove "wheel forks" from the sides of the steering shaft leaving the shaft full length.

Bike Frame:
• Cut the bike frame six inches from the headset.
• Stamp the frame ends flat inline with the vertical axis.

3. Grind the edges of the now flattened frame tubes to receive rudder sheet metal. Drill holes in the center of the flattened tabs for a 3/16-inch pop rivet.

4. Disassemble the crank assembly and the steering column.

5. Place all kinetic components into a small tub (with a lid) of solvent and soak. Clean grease and rust off the bearings and threaded parts, etc. with a wire brush. Note: Wear rubber gloves, respirator and goggles when using solvents. Adequate ventilation is required.

6. De-bur and grind all edges smooth.

7. Cut to dimension all metal parts:
Windmill body:

• One 3/8" x 1" flat bar 5-1/2" long to hold "motor" in line with windmill frame
  
• One 1/2" x 1" C-channel to mount flat bar at right angle to windmill frame
  
• Two 1-inch copper plumbing end caps

Tail section:

• Two 5/16-inch diameter steel rod to 32-inch lengths to become rudder spins.
  
• Four 22-gauge copper tabs 1-1/4" x 3-1/4" to hold rudder into frame.
  
• One 20" x 30", 24-gauge mild steel sheet metal to become moon face.

Mounting pole:

• Two 1" x 1/8" x 3" flat stock, drill two 1/4 inch diameter holes 1/2 inch from ends on center
  
• One 1/2" x 5' black steel pipe
  
• One 1/2-inch course thread nut for top of mount pole

Propeller/hub

• Three 22-gauge stainless steel 13" x 6" cut to shape of propeller blades
  
• One 1/4-inch diameter steel rod 13 inches long to become nosecone corkscrew

8. Grind all edges and prep for welding.