Here are two good links on Van de Graaf generators:
Howstuffworks.com - How Van de Graaf Generators Work
A simple homemade Van de Graaf generator
I first built a generator similar to the one shown in the link above - A simple homemade Van de Graaf generator. I had several problems; it was difficult to make adjustments, the glass tube (fuse) on the top broke easily, and the rubber band wore out easily. Therefore I did several experiments and found that this odd generator design here I made worked. This generator I made has no PVC enclosing the rubber band and was simple to adjust. A plastic straw for the "top" roller was used instead of the glass tube (fuse). A small bowl is used for the topload. The average spark length from this generator is about 2 to 3 mm long. The motor I used came from a 1500 watt hair dryer and works well with 20 to 30 volts.


Top view

2-3mm sparks