4.4. Corona Shield Assembly
1. Because the legs will hang down below the base in the first phase of construction, you will need to elevate the base. I find that three 2-L soft-drink bottles are just the right size to support the base (a). The "front" of the generator has a small hole for the pulley. In addition to the holes at the corners and at the center, there are two 5/8-inch holes in the back-left and front-right corners.
2. The main bearing is supported by a short length of half-inch CPVC tubing (b). Main bearing (c) is force-fit onto one end of the main shaft (d).
3. Apply some glue to bearing support (b) and insert it from below. into the hole in the center of base (a). The goal here is to avoid getting any glue on the bearing itself. Insert the bearing into the hole and adjust the bearing support until the bearing sits flush with the top of the base.
4. The corona shield (e) will eventually be supported by two legs (f), each of which have a slot near the top. Insert these slotted legs into the holes in the back-left and front-right corners of the base. Slide the main axle into the hole in the center of the corona shield and insert its corners into the leg slots. Note that the corners of the corona shield are not identical; those at the front-left and back-right corners clear the corner holes completely; those at the back-left and front-right fill the slots in the legs.
5. The upper bearing (g) consists of a short length of plastic tubing. Slide it down the main axle and insert it into the hole in the corona shield. You may glue it later, but for now let it be held to the shield by friction alone.
6. Lift the corona shield from the base, allowing the legs to slide upward in their holes, and insert four copper elbows (h) between the base and the shield. These provide temporary support for the shield while the collectors are assembled. Insert a tee (i) onto each of the remaining un-slotted legs (j) and slide the legs into the front-left and back-right corners of the base. Assemble tube (k)(1.25-inch), elbow (h), and tube (l)(8-inch) to form the collectors as shown. Lever tube (l) to a vertical position, apply glue to the underside of tee (i) and elbow (h), and return it to the position shown.
