A home-made wind tunnel sounds like fun. You will likely need some straightening vanes between the fan or blower to laminarize the flow. As far as calibrating the tunnel, you could look at hot-wire anemometers, or maybe the HVAC industry has something you could use.
Here are some things I've learned about cup anemometers: In theory, the swept circumference of the cups travels at the same speed of the wind. It helps if you think of the cups as a wheel, and the wind as a road.
In practice, the cups always spin slower than the wind due to aerodynamic drag and bearing friction (except for the case of over spin caused by a big gust followed by a lull or such). Well characterized anemometers have a correction factor to get the "true" wind speed from the indicated one. Davis mentions theirs in a app note.
Back to the first point... The larger the diameter of the cup wheel, the slower the revolutions for the same wind.
The larger the cups, the lower the threshold. My copper add-a-mometer has a lower threshold than the Davis right below it due to cups (4" diameter vs 1.5")
Cup geometry has a small effect. I read a study from the 40s I believe, that elliptical cups were better than hemispheres.