Sometimes, the plastic fan blade of a fan can be prone to breaking, rendering the fan useless, even though the motor is still able to run well. A non-functioning fan can be very inconvenient, especially when all you want to do is cool off on a hot summer day. So what now? Thankfully, it's quite easy to make your own fan blades out of cardboard.
In this tutorial I will show you how to craft my simple and efficient 2-blade design, but feel free to experiment with other designs of your own choosing (e.g. number of blades, shape, etc).
This is my 1st Instructable tutorial, so feel free to leave some feedback if you wish.
Step 1: Gather the materials and tools
These are the materials and tools you need to craft a cardboard fan blade.
Required materials and tools:
Step 2: Design the blades
In my case, I experimented with different fan designs to see which one would produce the most wind.
Depicted are 4 prototype fan blades.
From my experience it seems that the fewer the number of blades, the stronger the wind produced.
Step 3: Cut out a blank square piece of cardboard to work on
If you've got a pizza box, dissect it. Cut out the top bit (which is usually not oily). Else, just cut a square piece of cardboard out of a box, roughly the size of your fan.
Step 4: Draw the design
The following instructions are for if you want to make my 2-bladed fan design. I have provided a schematic of my 2-blade design to make it easier to understand.
Next, draw another arc with its centre at the other intersection, starting at the far side of the centre circle.
Step 5: Cut out the design
Now that the drawing is done, it's time to cut it out!
Step 6: Cut out the circular blade 'hub' parts
Draw 2 circles on the bits of the leftover cardboard from the previous step, then cut them out.
Step 7: Puncture holes and cut slots
Now we need to find a way to puncture the holes in the blade, so that it can slip on the motor shaft easily.
Here's the method I used:
To ensure the blade engages with the pin on the motor shaft, cut 2 slots opposite each other in the larger circular piece, as well as the main fan blade.
Step 8: Glue them together
Using the glue stick, glue the 2 circular pieces to the main fan blade, ensuring that the slots on the blade and the larger circle match up.
Step 9: Bend the blades!
And the fan blade is done!
Step 10: Find a way to fix the blade in place
Since the final cardboard blade is much thinner than the plastic blade it replaced, the screw-on cap can't be used as-is without the blade disengaging with the motor shaft and slipping.
This is a simple cardboard retaining device that allows the screw-on cap to bridge the gap between cap and blade. What the device basically does is to help to hold the blade in place, acting as an extension of the plastic cap. I strongly recommend you create one of these.
The components of the device: 2 holders and 2 'sticks'.
The holes in the 2 holders can be made using the same techniques as shown in Step 7 earlier, while the 'sticks' are just simply rectangular pieces of cardboard of equal length, folded in half.
Step 11: You're done!
Sit back and relax as your rejuvenated fan circulates air around your room.