Rewinding A Car Alternator For 240 Volt

February 3, 2026 by Maya Posch No comments

Two phases installed on the stator. (Credit: FarmCraft101, YouTube)

As part of his quest to find the best affordable generator for his DIY hydroelectric power system, [FarmCraft101] is trying out a range of off-the-shelf and DIY solutions, with in his most recent video trying his hands at the very relaxing activity of rewiring the stator of an alternator.

Normally car alternators output 12VDC after internal rectification, but due to the hundreds of meters from the turbine to the shed, he’d like a higher voltage to curb transmission losses. The easiest way to get a higher voltage out of a car alternator is to change up the wiring on the stator, which is definitely one of those highly educational tasks.

Disassembling an alternator is easy enough, but removing the copper windings from the stator is quite an ordeal, as they were not designed to ever move even a fraction of a millimeter after assembly.

With that arduous task finished, the rewinding was done using 22 AWG copper enamel wire, compared to the original 16 AWG wire, and increasing the loops per coil from 8 to 30. This rewinding isn’t too complicated if you know what you’re doing, with each coil on each of the three windings placed in an alternating fashion, matching the alternating South/North poles on the rotor.

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The Many Questions And Challenges With DIY Hydroelectric Generators

January 6, 2026 by Maya Posch 66 Comments

The concept of building your own hydroelectric generator seems simple at face value: use gravity to impart as much force as possible onto a turbine, which spins a generator, thus generating electricity. If you’re like the bloke over at [FarmCraft101] trying to DIY this with your farm pond and a lot of PVC pipes, you may have some significantly more in-depth questions, especially pertaining to what kind of generator to use. This and other questions, some of which were raised after the previous video in which the first prototype generator was assembled, are answered in this follow-up video.

When you DIY such a hydroelectric system, you have a number of options when it comes to just the turbine design alone, with the Kaplan-style turbine being one of the most straightforward ones – especially if you use a fixed pitch instead of adjustable – but you can go pretty far in the weeds with alternatives. As for the sharp drop-off after the turbine in the used design, the technical term is a draft tube, which is actually more efficient in this kind of low head, high flow hydroelectric dam situation.

After getting his money back for the unusable ‘3 kW’ generator, there were three options left: try an EBay special, get a purpose-built one from a US company, or rewind an alternator stator for higher voltage output than the standard 12/24V. Ultimately option four was chosen, as in ‘all of the above’, so that comparison is coming up in a future video.

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How To Convert A Drain Into A Hydropower Facility

August 16, 2025 by John Elliot V 31 Comments

Over on his YouTube channel [Construction General] shows us how to convert a drain into a hydropower facility. This type of hydroelectric facility is known as a gravitation water vortex power plant. The central structure is a round basin which includes a central drain. The water feeds into the basin through a series of pipes which help to create the vortex which drives the water turbine before flowing out the drain.

To make the facility [Construction General] starts by laying some slabs as the foundation. One of the slabs has a hole to which the central drain pipe is attached. Bricks and mortar are then used to build the basin around the drain. A temporary central pipe is used for scaffolding along with some strings with hooks attached to hold the bricks and mortar in place for the basin. Integrated into the top half of the basin are fifteen inlet pipes which feed in water at an angle.

The next step is to build the dam wall. This is a bricks and mortar affair which includes the drain in the bottom of the wall and two spillways at the top. The spillways are for letting water flow out of the dam if it gets too full. Around the drainage in the dam wall a valve is installed. This valve is called the low-level outlet or the bottom outlet, and in this case it is a sluice, also known as a slide gate, which can be raised or lowered to control the rate of flow through the turbine.

Once the basin is complete and the low-level outlet is in place the scaffolding is removed. The basin is then painted, pink on the inside and white around the top. A turbine is constructed from various metal pieces and installed into the basin. The turbine is attached to a generator which is fixed atop the basin. The apparatus for operating the low-level outlet is installed and the dam is left to fill.

Hydropower is a topic we’ve covered here at Hackaday before, if you’re interested in the topic you might like to check out A Modest But Well-Assembled Home Hydropower Setup, Hydropower From A Washing Mashine, or Bicycle Hub Hydropower.

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Hydroelectric Generator Gets Power From Siphoning

January 21, 2025 by Bryan Cockfield 42 Comments

Siphons are one of those physics phenomena that, like gyroscopes, non-Newtonian fluids, and electricity, seem almost magical. Thanks to atmospheric pressure, simply filling a tube with liquid and placing the end of the tube below the liquid level of a container allows it to flow against gravity, over a barrier, and down into another container without any extra energy inputs once the siphon is started. They’re not just tricks, though; siphons have practical applications as well, such as in siphon-powered hydroelectric turbine.

This is an iteration of [Beyond the Print]’s efforts to draw useful energy from a local dam with an uneconomic amount of water pressure and/or volume for a typical hydroelectric power station. One of his earlier attempts involved a water wheel but this siphon-based device uses a more efficient impeller design instead, and it also keeps the generator dry as well. Using 3″ PVC piping to channel the siphon, as well as a short length of thinner pipe to attach a shop vac for priming the siphon, water is drawn from the reservoir, up the pipe, and then down through the impeller which spins a small DC generator.

This design is generating about 9 V open-circuit, and we’d assume there’s enough power available to charge a phone or power a small microcontroller device. However, there’s a ton of room for improvement here. The major problem [Beyond the Print] is currently experiencing is getting air into the system and having the siphon broken, which he’s solved temporarily by adding a bucket at the outflow. This slows down the water though, so perhaps with any air leaks mitigated the power generation capabilities will be greatly increased.

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E-Bike Motor Gets New Life As Hydro Plant

January 5, 2025 by Bryan Cockfield 52 Comments

For economic reasons, not every lake with a dam can support a hydroelectric power plant. Some rivers or creeks are dammed for flood control or simply for recreation, and don’t have the flow rate or aren’t deep enough to make the investment of a grid-scale generation facility worthwhile. But for those of us with a few spare parts around and access to a small lake, sometimes it’s possible to generate a usable amount of energy with just a bit of effort.

[Beyond the Tint] is building this mostly as a proof-of-concept, starting with a 1,000W hub motor from an e-bike that’s been removed from its wheel. A 3D-printed waterwheel attachment is installed in its place, and the fixed shaft is attached to a homemade ladder-looking mechanism that allows the entire generator to be lowered into the flow of a moving body of water, in this case, a small stream. A bridge rectifier converts the AC from the hub motor (now a generator) into DC, and after a few measurements and trials, [Beyond the Tint] produced over 30W with the first prototype.

A second prototype was made with feedback from the first video he produced, this time with an enclosed paddlewheel. This didn’t appear to make much difference at first, but a more refined impeller may make a difference in future prototypes. Small-scale hydropower is a fairly popular challenge to tackle, especially in the off-grid community. With access to even a small flowing stream and enough elevation change, it’s possible to build something like this generator out of parts from an old washing machine.

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Build Your Own Hydroelectric Dam

July 11, 2024 by Al Williams 21 Comments

We have to admit that we often think about building unusual things, but we hadn’t really considered building our own hydroelectric dam before. [Mini Construction] did, apparently, and there’s a timelapse of the build in the video below.

We wished this was more of a how-to video, although if you are handy with brickwork, the mechanical construction seems straightforward. Presumably, you’d need to understand how much force the water had but we don’t know if there was math involved or just seat-of-the-pants design.

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A series of trapezoidal steel "buckets" attached together to form a metal water wheel. They are arranged around a square center frame that attaches to a hub for the wheel to spin about. The wheel is next to a stream and four people of various ages appear to be talking around it. A cinder block building with a metal roof is in the left background, and an older, yellow stone building is far off in the distance on the right of the image. The landscape is lush, green, and mountainous.

Open Source Waterwheel

August 20, 2023 by Navarre Bartz 28 Comments

Here in the West, power going out is an unusual event. But in more remote regions like the Himalayas, reliable electricity isn’t a given. A group of local craftspeople, researchers, and operators in Nepal have worked together to devise a modular waterwheel system.

Based on a 20-30 cm-wide bucket module consisting of only four galvanized steel components, the wheels can be easily built and deployed using resources and tools that are easy to find anywhere in the world. Current test devices generate between 120 and 1,400 Watts of power, depending on the device’s size.

A software tool was also developed that takes the head and flow rate of a location as inputs to calculate the dimensions of the optimal wheel and expected power output for an installation. This lets communities find ideal sites for power generation and calculate the expected costs.

We’ve covered a few other DIY hydropower setups, from repurposed washing machines to custom scratch builds.