Dia. Mag. Alternator

[b_rads]

Z.Monkey
This project of yours is developing into a work of art.  With your permission, I would like to save a copy of your last pictures for wallpaper on my personal computer.  The rework on the gears is awesome.  Bummer about the coils!  You truly are Tenacious.   
Brad S

[z.monkey]

work of art.

LOL!  My artistic medium is steel, copper, and aluminum seasoned with physics...
You can use the pictures if you want.  Already got a plan for the coils...

[z.monkey]

I got the new wire on order today.  Its an industrial grade 14 AWG magnet wire, here are the specs...

http://www.belden.com/techdatas/english/8073.pdf

Looks like I'll be doing the unwind / rewind thing soon.

Then we make power...

[z.monkey]

I got busy taking apart the alternator on Friday night.  All the hardware came off nice.  The coils decided that they were an immovable object.  I did put these coils together with marine epoxy, so I didn't figure that they would be easy to take apart...

I got 9claw and Samurai to provide some muscle, and together we applied the unstoppable force.  It took a few hours to liberate the immovable object.  The core is steel, so I wasn't too worried about applying the Blacksmith Hammer and a sharp chisel to liberate the immovable object...

The last picture is the bits left over...

[z.monkey]

I've got a new way to apply the keepers this time.  I want to make the coils a little more narrow, so there are no problems with the hardware or tools used on the hardware.  The keepers will come off with the winding jig this time.  The coil will be epoxy filled, same as last time.  The larger wire should produce more uniform windings.  Also didn't add anything between the wire and the core this time.  I used a couple winds of electrical tape last time.  This wire is heavily armored, do there is no need for the intermediate material.

Ready to rewind...