Dia. Mag. Alternator

[z.monkey]

Here are the Threaded Inserts, and the new Mini Studs.
On the left you can see the T-Slot Nut with the Threaded
insert installed.  There are slots in the top of the threaded
insert for a screwdriver.  Don't do it...  Instead I installed
them with a the hardened stud and flange nut.  Using a
flathead screw driver only messed up the slotted edges,
and I cross threaded one of them.  Using the Stud and
Flange Nut allowed me to use a wrench instead of a screw
driver.  The wrench allowed a much easier insertion.

In the center is the new 1/4 inch Mini Stud T-Slot Nut,
and on the right is a 1/2 inch Stud in a T-Slot Nut.  Also
you can see the difference in the Flange Nuts...

[z.monkey]

Now I have the wire form plates clamped on the table and am
cutting the straight line.  There are 3 clamps holding the work
piece to the table, so its very rigid.  I use the X/Y screws to
line up the cuts, cut a series of holes on the Y axis, and then
run the side mill up and down the slot on the Y axis a couple
of times, adjusting the X axis to cleanup the scallops...

[z.monkey]

Cut the outer radius of the wire form this morning, and started
cutting the slots.  Plan to finish the slots this afternoon and
do the inner radius.  The slots are a lot cleaner when you have
both ends closed at the time of cutting.  After all the slots are
cut I'll open the inside end (inside radius)...

[z.monkey]

OK, got the Wire Form Plates cutout, rough cut anyway.
Now starting on the Bearing Mounting Plates.

[Cap-Z-ro]

Kinda reminds me of the layout of the Model T magneto Z...you are really putting a lot into this...hope you find success.

Regards...