Dia. Mag. Alternator

[z.monkey]

Here I am marking the holes to cut on the winding jig, and fitting the winding jig to the stack.  Next I need to fabricate the coil keepers.  Also I need to make the end pieces for the winding jig.  The end pieces will use a 1/2 inch threaded rod for an axle to allow the winding jig to spin.  Then I'll make a crank with another stick of wood, another piece of the threaded rod, and a 1 inch dowel as a handle.

I think I can see light up ahead in this tunnel...

[nievesoliveras]

Excellent!

[shylo]

Very Nice work,....looking forward to see,..how it preforms....and produce's power..........pretty much the same thing.............I think you might have a portion that locks up on you though,......I hope I'm wrong................shylo

[z.monkey]

Today I fabricated the Winding Jig End Plates, and then built the rest of the Winding Jig.  Now we have to get everything square, glue in the coil keepers, and then torque everything down before we wind the coils...

[z.monkey]

OK, this is the winding process.  I had a couple friends help with the winding process because I need more than two hands to do this.  One was the glue man, and managed the epoxy coating on the windings.  The other was there to count the windings.  It took a good three hours to wind the two coils.  They each have approximately 1060 turns.  I used a long cure epoxy (60 minutes) so that we would have extra working time.  I have had problems with the epoxy curing before I got the coil wound before, and didn't want that to happen here.  This was a rather sloppy process, and we had a few SNAFUs where we had to unwind part of the coil, after it was coated with epoxy.  Its never fun to get epoxy all over the place.  Albeit we got the thing wound and that's the important part.  The Epoxy requires 24 hours for a full cure, so I am not going to take the core out of the winding jig until tonight...