- 1). Cut your PVC pipe in half lengthwise with a hand saw to form a half tube. Set aside. You will later use the PVC pipe as a mold to shape the metal of your windmill blades -- it will not be part of your final product.
- 2). Calculate the size of your blades. The length of your blades will depend on how many you want and how tall your base is. The length of each blade should be no more than 1/3 the height of your windmill base. Some windmills are made with several shorter blades placed closer together, whereas standard power generating windmills often use three long, slender blades. For this article, the windmill will be 20 yards tall, and will have 20 shorter blades each measuring 3 feet long by 6 inches wide.
- 3). Measure one rectangle on your sheet metal for each blade, based on the dimensions you formulated in step 2. Cut out each rectangular blade. Drill holes in each of your blades to use in mounting them to your windmill base. The position and number of holes will depend on how you plan to mount them to the base.
- 4). Line up the bottom and top of each blade one at a time with the ends of your PVC pipe and bend the sides of the blade to curve around the pipe. Your blades are now ready to be attached to your windmill.
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