Coupling Help

Hi everyone!

I have a request; A customer is wanting to put a coupler on our stainless shaft which has standard threads, 5/8 NF 18 tpi. It sounds like he is wanting to go to metric threads.  Have any of you done this or does anyone have any ideas?   The shaft does have a keyway.  Maybe that can somehow be utilized?

Thanks for your help.





Back by Popular Demand!

We have listened to you and have brought back the original Cy-Clone Kits, featuring TLG Windpower blades.

The TLG Blades are wider at the root (8″) than other blades which means more torque at lower wind speeds.  Having only 2 blades increases the rpm/mph ratio.  Our tests show that with our PMA’s, which have a stainless steel shaft, we get 25 rpm/1 mph wind.  The TLG blades unique curve catches the wind better and does not create drag at higher rpm.  The wind still spills out at extremely high speeds so a brake is not necessary.  As before, the blades are made from 1/8″ aircraft quality, aluminum and the hub from 3/16″ stainless steel.

The mount design is ours and we manufacture it in our Indiana shop.  The mount is made from 1″ square steel tubing and the tail fins are steel.  Both are primed and ready to paint.

We do have a fairly new design change in our PMA.  A few months back we started incorporating a keyway in the shafts.  We are very happy with the outcome and now the blade hubs have a slot for the key.  Although it is still critical to have a tight fit between the shaft nut and the case the key ensures that the blades do not slip.

All the pertinent information can be found on our website,

Thanks in advance for your feedback.  You can leave comments or questions here or visit our discussion board,



Once again WindBlue Power is leading the way in Permanent Magnet Alternator design.  We were the first to use Stainless Steel shafts and now we are putting a keyway in them.  The stainless shafts on our DC-500 series now have a 5mm x 5mm x 12mm keyway and come with one Feather Key.  So now if you order a DC-500, DC-512, DC-520, DC-540, or a rotor, it will come with a keyed shaft.  The pulleys have a slot for a more secure fit.  This will also make it easier for counterclockwise rotation.  You won’t have to worry about the shaft nut loosening up and damaging things. It will also be useful in applications such as a lovejoy.  And at the same low price as before!  If you should lose the key we have them for sale on our site.

Please note that the pulley, spacers, etc. must still be sandwiched between the shaft nut and the front bearing spacer.  If they are not snug they will spin on the front bearing and your PMA will be damaged.

The DC-400 series ( DC-420 and DC-440) will not have a keyway.  They are still the basic steel shaft with the GM threads.

Let me know what you think.  I’m always open to constructive ideas and comments.

Think Green, Go Blue!

Complete Kits

I’m sure you have noticed that “Complete Kits” have been removed from our category list.  Our aluminum blade supplier has discontinued them and so far we have not been able to find a suitable replacement.  We take pride in selling quality products.  So far we have not found composite or plastic blades that meet our standards.  So we have no choice but to discontinue the kits for now.

We have also decided to take the mounts off of our site.  They are our unique design and we are concerned that they will be used with inferior blades and PMA’s that will harm our reputation.

We still have a few of the Hyper Spin Blade Kits available.  When they are gone there will be no more.  We do have a few used but good blades that we are going to keep for replacements.


Pedal Power

After many, many questions concerning the feasibility of using a stationary bike to charge a battery with one of our PMA’s we decided to give it a try.  I’m delighted to report that it was a success!  I was elected to be the one to pedal.  Not because I’m in such great shape, just the opposite.  I was chosen because I’m old and out of shape.  If I can do it anyone can.


We decided to try a gear ratio of 7.5 : 1.  As I’m sure you know, the higher the ratio the more torque required, which means more work for these old legs.  I had no problem  with the gearing.  If someone was in better shape than me (which is almost everyone), they could probably up the ratio if they wanted.  The fact the it is an elliptical with upper body function probably made it somewhat easier but like I said, I’m old.

We used a DC-520 PMA on a Confidence Fitness Elliptical.  I  was able to produce  5 amps with a minimum amount of effort.  Since it is easy to keep an eye on the battery state with a meter we do not recommend a charge controller.  It is an unnecessary expense. We did not measure the rpm, just used the LCD meter.  We also tried the DC-540, our lower rpm model.  It worked also but with no more effort I could produce more amps with the DC-520.

As you can see from the pictures we removed the large front wheel from the bike since it is for show rather than function.  It was just a large piece of plastic.  If it was an actual fly wheel we would have utilized it.

So if you’re considering making use of that stationary bike go right ahead.  I have had customers make them for their kids:  they would have to charge a battery in order to watch TV or play their video games.  It’s also nice to have as an emergency charger in case your power is out due to storms.

Thanks for reading, you can see more pictures of this project on our site,, generator ideas.

Think green, go blue!