Newman Motor - tinkering and teething problems

[Spirality]

Yes you got the basic idea on coil taps. Here is how I do it. After winding , say, 25 turns , double the wire back on itself for about 2 inches, and then twist the two resultant strands together. Then carry on winding. The result is a "spur" or branch sticking out from the coil. You only need to strip the insulation from the end of the tap if, and when you decide to user it.
     A useful idea is to add taps after 5 turns, 10, 15,20, and 25 turns. After that, tap every 25 turns. By using various taps you can vary the total turns over a wide range, and use the early, fine taps for fine tuning.

Thanks for the advice, I'll probably do longer taps and label them, it will be easier later.
I'll be using fine wire so at the end of every layer of turns I'll fold the projecting taps down flat, and bring them all out sideways like a ribbon cable, so I can keep winding over them.

The plan is to add taps as you suggest up to around 300-500, then in steps of 100, and it would be better if the tap legs were tucked out of the way. I have a pound (2x250g) of .236mm wire (34swg) for both coils, and a home-made winding jig. I'll be ready to do a few thousand turns.

Do you reckon its a good idea to vary the tap frequency from 25 to 50 and 100, or do it all at 25?
I am also considering a small bit of glue to hold the tab leg together at the bottom, in the windings, to complete the 360^o of a turn. My concern is that the wire will be too thin for a normal twist to hold it together. I may also see about winding it with a physical overlap instead, or a bit of thin tape, to tighten-down the tab base.

I would also like to build an outer rotating armature, and place extra Magnets on it facing the inner core magnets. I can easily visualize a stream of magnetic flux between them and the magnetic core, passing through the wire at 90^o as it rotates. This will facilitate the electro-gyroscopic motion of the copper atoms over the widest area at the best angle, especially with bar magnets of a certain polarity. It may be useful (or not) to add taps at both ends of the Coil, with that inner-outer magnet arrangement....

An Electrical Professor friend and I were turning the latest motor conventionally with the Reed Switch Setup, on 51 volts from Golf Car Batteries. For a few seconds it accelerated giving big sparks on the Reed, before the nail began sticking to the copper contact. Both have a layer of soot now. She suggested a normal Relay as the switch, or a light spring against the nail.
I would eventually prefer to power it by JT.  Am curious to hear what other People's in/out Voltages are.

Cheers
Spir