In this article, detailed design and manufacturing processes/materials are presented for the prototyping of a cost-effective open-circuit wind tunnel. Students and educators can use it to enhance their understanding of aerodynamics concepts by enabling them to perform a variety of experiments, such as flow visualization, drag, and lift measurements, and boundary layer studies. The design of the settling chamber, contraction cone, test section, and diffuser are based on empirical parameters suggested by the literature available in this domain. Fabrication was done by using materials and components easily available locally. The final prototype of the wind tunnel is tested and calibrated to ensure accurate and reliable measurements. To validate the performance of the wind tunnel, a series of experiments were conducted, comparing the obtained results with established theoretical models and existing data. The affordability and accessibility of the wind tunnel make it particularly suitable for educational institutions with limited resources.