
photo www.schloerb.com
Sabalo Eco Lodge is located in a unique environment within the Osa Peninsula. Living off the grid requires us to generate our own electricity. We need enough electricity to power two computers, Satellite Internet, a small fridge, a few outlets in the main lodge and energy efficient florescent bulbs through the structures. We have a robust solar system but because this area gets an average of 200 inches of rain a year (mostly October to mid December), solar power does not work as well on the very rainy days.
Our property is a flat open eight acres next to lowland primary rainforest and mangroves. We have a fairly fast moving stream that curves around one side of our property as the water heads out to the mangroves. This stream flows all year round and we have been trying to figure out how to use the force of the stream to create electricity.
Holly mentioned the challenge to our friend Johnny who is a Tico living in San Jose. He and his mother run a family business that does die cast lighting fixtures for hotels, commercial properties and residential homes.
Johnny had built us a custom trailer to haul our two ATVs and motorcycle; projects he likes to do on the side when business is slow. He decided to take on the challenge – armed with the internet, a brilliant mind and a can-do attitude, Johnny amazed us with his water wheel/brake drum alternator solution and thus the inspiration for the title of this article.
In order to generate electricity you first need an alternator. Johnny found his inspiration for the idea on the web. Someone was converting a brake drum from a car into an alternator. Here’s Johnny’s original email to us with pictures of his alternator constructed from a break drum, magnets, wire and a few other items, MacGyver would be proud…….
Let There Be Light!
Hi Holly,
Well… here you have the pix of the Frankenstein’s Alternator
I’ve just tried to follow the designs shown in the website I’ve told you at http://www.otherpower.com/otherpower_experiments.html. The only difference is that I used a slightly smaller (and a lot cheaper, I’m an eBay bargain hunter you know…) 1.5″ x 0.75″ x 0.25″ rectangle magnets instead of the 1.8″ round or 2″x1″x 3/8″ rectangle magnets they use. It’s supposed to start charging at less than 200 RPM instead of 410 RPM, but it is still low rpm compared to a car alternator which requires around 2000 RPM. I also used 14 AWG magnet wire with 60 turns per coil as they did, so the output voltage depends on the number of turns and the strength of the magnetic field. Coils with thinner wire and more turns will produce more voltage at the same RPM, but less Amps.

Below is the alternator viewed from the back. As you can see the roll of steel laminates (scrap metal strips used to tie down things on pallets) makes the stator produce more power by “aligning” the magnetic field across the coils that are “sandwiched” between the rotor and the laminates. There is also a design that uses a second disk brake rotor with a second set of magnets instead of the laminates that doubles the power output, but it´s a little bit more complicated…

The DC output can be connected directly to a load like the bulb shown or an inverter to power 120 V AC devices (I’ve already tried it with mine to turn on a 120 Volt CF bulb, believe me, it was very funny…) but is necessary to pedal at a constant rate (RPMs) to keep the voltage within the operating range of the inverter (11 to 14.5 volts). So the best option is to connect the DC output to a charge controller and a battery (or bank of batteries) to store the power.
Below you can see the entire assembly made of scrap metal from my roof project (hehehehe…. more free parts…). I just removed the front wheel because I’m not going anywhere…
I calculated the RPM´s using the bike’s digital speedometer (making the conversion from km/h to rpm).

Here is the alternator in action… (it’s quite difficult to show the movement in a still picture, isn’t it?)

So, the alternator was connected to the bikes back tire to power it with motion which created electricity, yeah! Now that the alternator works next question is, “how to build a waterwheel and connect the alternator to it”?
Powered By Nature
Johnny being the thrifty inventor that he is quickly figured out the solution for the water wheel using an old wooden cable spool.

As you can see, it has cast aluminum brackets holding the PVC paddles in place.
It also has one coat of sealant and two coats of marine grade varnish applied to the wood structure. Now, it’s time to mount the entire assembly on a metal frame and add the necessary shafts, bearings and sprockets to step up the RPM´s for the generator.
It was decided that the best solution and least intrusive on the environment would be to create a floating platform for the water wheel. The platform would be buoyed using plastic or metal tanks. The last item to figure out was the sprocket and chain mechanism to turn the alternator using the force of the waterwheel. Here’s what Johnny came up with.

The alternator to the left is connected to the waterwheel by a series of bike sprockets and bike chains. This allows the rotating motion of the waterwheel, powered by the motion of the stream, to turn the alternator and create electricity. That will flow from wires to our battery bank where it will slowly charge our batteries 24/7.

Johnny added metal drums for this picture to demonstrate how the platform works. We intend to have plastic barrels. Johnny also built a metal cover for the gears and alternator to protect it from the weather. We will be picking up our new sustainable source of electricity very soon. We can’t wait to get it installed. Johnny, amazing job… thanks!
Bonus Water Pump!
Johnny apparently wasn’t finished yet and came up with a device I have been trying to figure out for four years now. I’ll Let Johnny tell you about it…..
“Meanwhile I’ve also thought about what to do with the other end of the main shaft of the waterwheel and I made a small but effective water pump using 4 standard 1/2″ check valves, PVC fittings and an old stainless steel pneumatic piston (I’ve collected a lot of pistons few years ago because they came along with a lot of aluminum junk). You have to see that! (I haven’t taken pictures yet). It takes a small amount of water (about 20ml. per strike = approx. a bucket per hour) but with the high torque at the shaft it’s possible to pump water very high (high-pressure – low flow). So if you want to attach it to your water system, just add the proper filter, fittings, and hose to match your existing pipe, and you’ll have a 24/7 sustainable water pump filling your tank. Don’t worry about the cost (donations are accepted, money back guaranteed…).
Not using your gas powered water pump… Priceless!”
We’ll post picks of the piston water pump when we get them and let you know how everything works out once it’s installed.
Thanks for reading our post.
Dan & Holly Pesta
www.sabalolodge.com