How to Build Windmill Fans

Learn to build a set of replacement fan blades for vintage wooden windmills with these tips

| June 2010

A  year or so back, Lowell Devries from Historic Prairie Village museum near Madison, S.D., asked if I would build a set of fans for a Baker Monitor Vaneless Model L windmill there.

I told him that as soon as we had another three-day blizzard, I would make him a set. Well, around Christmas 2009, we had one. By then I had two sets to make: One for Prairie Village, and the other for a Pipe Raymond that we had gathered up for our museum.

Bill Lee, curator at the Ag Heritage Museum on the South Dakota State University campus in Brookings, came up with an extra set of Pipe Raymond fans (with hardware) that he donated to me. Generally, fan hardware is lost, buried in the dirt where the mill fell or was dumped. Scrap dealers pick up the large pieces, but small pieces are lost under the grass. Dan Benjamin, Freeman, S.D., deals in old mills. He had parts I needed for the Pipe Raymond, and I had some parts he needed, so we both came out ahead with no money involved.

The right saw blade

Building fans is not a complex process, nor are specialized tools needed. The most important item to have is a 3/4-inch-wide blade (with three to four teeth per inch) for your band saw. When re-sawing, a wide blade keeps the cut going straight as it runs into the wood’s grain (photo 1). This cut is not smooth, but no one will be able to tell that, looking up 30 feet or so. The idea is to get five blades from a blank (more on this later), ending up with just a shaving left over.

Blades can be made from almost any wood. Years ago, cedar, cypress and redwood were commonly used, but some manufacturers used fir to save money. Most builders dipped fan sections in white lead-based paint a time or two to preserve them. When you find an original fan section, the paint is often thick where it puddled after being dipped.

Creating a guide

Blanks are made by cutting a 2-by-6 on a diagonal (photo 2): Make the narrow end 1-1/2 inches wide and that ensures a width of about 4 inches on the wide end. If you cut the first pair carefully, you’ll have blanks to use as guides for the rest. Nailing a cleat on the pattern blank will keep everything in line as you saw each 2-by-6.

The saw blade for the circular saw cutting slots has a kerf of just under 1/4 inch (photo 3). Getting blades the right width is a cut-and-try operation. Use scrap through the band saw and adjust the fence until the blade section will go snugly into the slot. If it’s too tight, you’ll break off wood between blade slots.

6/6/2011 8:15:10 AM

Hi Charly O, You can find the referenced pictures in the photo gallery by clicking on the "Photo Gallery" link under "Article Tools" or by going to

Charly O
6/5/2011 7:29:25 PM

I am interested in learning moved about building these fan blades. In reading the article at the referenced pictures were not shown. Is it possible to get a link to the pictures? If so thanks!