Dia. Mag. Alternator

[z.monkey]

Just now got the Rotor Magnets installed.  That was a sticky situation.
I used 5 minute epoxy.  Got all the magnet lined up on the fridge.
Then spread a thin layer of epoxy on the rotor.  Added a pair of
magnets at a time.  When the ring was complete, I spent the rest
of the cure time cleaning up the goop, and aligning magnets.

After it was cured I fit it in the stator.  The stator was a little off,
and I needed to file down some high spots.  Its still a little funny,
but the rotor spins.  I'll clean it up a little more tomorrow...

[z.monkey]

I had made some holes in periphery of the stator plates.
They accommodate the wire management dowels.  They
help guide the windings where they need to go.  Also
needed to use some spacers to add phatness to the
dowels.  The first winding looks pretty good.  I'll be getting
some more practice in the near future....

I also added the vinyl inserts in the slots, like on DiaMag7,
to isolate the windings from the aluminum parts...

[z.monkey]

OK, got the stator wound.  It probably took a full day to wind it.
I want to find a better way to do the next one.  The wire management
sticks dowels moved around a lot.  I think the wire looks kind of
sloppy around the periphery.  In the slots it looks great.  Some of my
vinyl inserts are dragging on the rotor.  I'll use a side cutter to trim
out the extra bits.  Also got a shot of it assembled...

[Cap-Z-ro]

Certainly looks mean Z...hope its a success for you.

Regards...

[z.monkey]

Hey Cap,
Like angry, sinister?

Insert righteous political outrage here...

If you ask my wife, its a toy, that and all the tools, just toys...