Dia. Mag. Alternator

[z.monkey]

Here is the finished pinch coil...

[z.monkey]

So the green coil I wound on Friday is Too Fat!  Doh!

I made hasty measurements in the morning before work, and then built the coil in the few bits of spare time I could muster.  I was rushing, and forked up the coil.  I hate it when I do that...

[z.monkey]

It is almost 1/8" too big.  So, well, guess were gonna do it again.  I still have some plastic from the relay cover.  So I'll build some new sides.  A found some aluminum tubing that I cut to 1/4" inch to be the core of the new bobbin.  Also I didn't glue the sides and the core together this time.  Instead I applied epoxy generously inside the coil a I was winding it.  This way the coil, the core and the sides are glued from the inside.  This makes it a composite coil...

[z.monkey]

I am also using 1/4-20 hardware this time, so the inside diameter of the coil is larger.  The outside diameter stays the same, 3/4" because we still have that finite space we have to conform to...

[z.monkey]

Now the coil fits in the pinch with around 1/32" (0.031") clearance on each side.  Good, finally fits, now we have to modify the mounting plates to secure the coil...