Hand-cranked Windmill Assembly Instructions copyright Mechanical Kits Ltd. 2011

Contents of Windmill Kit Wooden pieces (⅜” cross-section): 4 X 11¼”; 10 X 2¼”; 4 X 1¼” Green corner gussets: 3 cards Wooden dowel, 3/16” diam.: 8 X 3”; 1 X 1” Wooden dowel, ¼” diam.: 1 X 3½”; 2 X 2¾”; 1 X 2½” Medium wheels: 1 (drilled) Wooden Hub: 1 2” Pulley: 2 1” Pulley: 2 Axle Holders: 12 Spatulas: 8 Rubber bands: 3 Mini-washers: 7 Stirring Sticks: 1 Plus a small piece of sandpaper copyright Mechanical Kits Ltd. 2011

From one of the sheets of green corner triangles or gussets mark and then cut 8 “double” gussets as shown below. Put them on one side for later. Cut the remaining single triangular gussets from the sheet. copyright Mechanical Kits Ltd. 2011

Using two long (11¼”) pieces and two short pieces (2¼”) form a rectangle with outside dimensions of 11¼” by 3”. Using a small amount of wood glue secure the four corners with triangular corners or gussets. While this dries, repeat the process and make a second and identical rectangle. Turn the first rectangle over and secure the corners with four more gussets, then repeat the process for the second rectangle. Allow the wood glue to dry! copyright Mechanical Kits Ltd. 2011

Using one rectangle only measure and mark across the frame and on both uprights distances of 3”, 5½” and 8” from the outside edge of the bottom of the rectangle. Place three 2¼” pieces in the frame so that their bottom edge is aligned with the marks. Secure with six gussets as shown and then, once the glue is dry, six more gussets on the other side. copyright Mechanical Kits Ltd. 2011

Once the first rectangle is completed lay it on the other rectangle, mark both sides of the second rectangle and glue the gussets in place. The cross struts must be in the same position in both rectangles. copyright Mechanical Kits Ltd. 2011

Using one rectangular frame only, draw a line along the inside edge of both uprights on one side of the rectangle. This will enable the three gray axle holders to be aligned correctly. Glue these in place so that their longer sides align with the bottom edge of the cross struts and the lines. copyright Mechanical Kits Ltd. 2011

Turn the rectangle over and place it on the other rectangular frame as shown below. Using the three ¼” diameter dowels to align three more gray axle holders vertically and horizontally, glue them in place on the other side of the frame. It is important to ensure that, once dry, the axles turn freely. copyright Mechanical Kits Ltd. 2011

Once the gray axle holders are securely in place on the first frame and the wood glue is dry, place the second frame on top of the first and glue three axle holders in place using the ¼” dowels to ensure vertical and horizontal alignment. When these axle holders are securely in place, turn the second frame over and glue the three remaining axle holders in place. copyright Mechanical Kits Ltd. 2011

Viewed from a different perspective the two frames will look as below. The shortest ¼” dowel (2½” long) will eventually hold the double pulley, the longest (3½” long) will be positioned at the top and hold the single small pulley, while the other dowel (2¾” long) will be positioned at the bottom and hold the single large pulley. copyright Mechanical Kits Ltd. 2011

Remove the dowels from the two frames and set the frames on one side for later. Using the shortest ¼” dowel (2½”long) push the double pulley onto it so that it is positioned in the middle of the dowel. If the dowel is too tight use the sandpaper to reduce its diameter. Mark the dowel on both sides of the double pulley. copyright Mechanical Kits Ltd. 2011

Remove the double pulley and set it on one side and the position the dowels as shown below so that one end of the dowels are flushed. Using the marks on the smaller dowel mark the other dowels as shown. This will enable the pulleys to be correctly positioned on the dowels. copyright Mechanical Kits Ltd. 2011

Make sure that the pulleys are a “push-fit” on the ¼” dowels by sanding the dowels as necessary. Using a small amount of wood glue and the marks on each dowel glue the pulleys into position so that the double pulley occupies the smallest dowel, the small single pulley the longest dowel and the single large pulley the other ¼” dowel. copyright Mechanical Kits Ltd. 2011

Once the wood glue is dry and the pulleys are in position place the pulleys within the frame with two elastic bands. Each elastic band goes around a small and a large pulley as shown below. It is not possible to put the elastic bands in the model at any other step other than this one. copyright Mechanical Kits Ltd. 2011

Using the four smallest pieces (2¼” long) and a very small amount of wood glue on each end of each piece, create the tower structure as shown below. The dowels will hold the frame to some degree to ensure that the small pieces are correctly positioned. copyright Mechanical Kits Ltd. 2011

Use four of the eight “double” gussets and a small amount of wood glue on each to secure the corners at the top and the bottom of the tower. Fold the “double” gussets in half and secure one to each corner where there is no gusset in place. copyright Mechanical Kits Ltd. 2011

While the tower is drying glue the small dowel (1” long) into the wheel as shown below. copyright Mechanical Kits Ltd. 2011

While the tower is drying also mark the eight spatulas with a line 1¾” from one end. Carefully glue a 3” length of dowelling to each spatula so that one end protrudes 1¼” from the marked end. The spatulas are the vanes of the windmill and it is very important to allow them to completely dry before the next step. copyright Mechanical Kits Ltd. 2011

Hold the dowel part of each vane and put a small amount of glue on its end. Insert the dowel into one of the holes of the hub. Continue until all the vanes are in place. If one of the spatulas comes away from its dowel in the process glue it back into place. Make sure the vanes are orientated in the same way. copyright Mechanical Kits Ltd. 2011

Once everything is dry the final assembly begins. Carefully push a mini-washer onto the dowel that protrudes from the top of the tower until it almost touches the axle holder there. Then the hub and vanes are connected and glued to the top dowel. copyright Mechanical Kits Ltd. 2011

The wheel is connected and glued to the other side of the tower and to the bottom dowel. The elastic bands are put in place and the ends of the dowels are finished with the mini- washers. copyright Mechanical Kits Ltd. 2011