Nice motor and will follow your adventures with interest. Reading your, Flux and Oztules' responses has taught me a new thing or two again :)

I'm still looking for an (affordable) copy of Rosenberg myself. Parts of it can be read online and they certainly seem very interesting.

All the motors I've taken apart so far had only one coil leg per slot, so I suppose that method is really more common over here (Europe). In fact, until your post, I didn't know any better than that this was 'normal'. Another thing that continues to surprize me (and makes me jealous) is the fact that North-American motors tend to have a larger diameter-to-length ratio; the rotors are shorter but stubber. This should make for a better slow-running multipole genny. If you have a look at my 4-pole 3 hp conversion, you'll see that the rotor is much more slender: http://www.anotherpower.com/gallery/3HP-induction-conversion/motor_rotor_frontside

Was a bit surprised by Flux's remark that flux density of the 500 W conversion was low. It's nearly 1 T in the airgap above the magnets, whereas I understand that axial fluxes operate more in the 0.7 T range. (http://www.anotherpower.com/gallery/album69/blue_boy_FEMM_detail_average_flux_over_one_active_tooth)
But I must admit, I could have made airgap smaller, just that I have limited faith in my machining/building capabilities :) I don't recall having done a definitive FEMM simulation of the 10 hp conversion; that's another thing on the 'to-do' list for this weekend then...

You haven't explicitly stated so in your story but I understand you will use the stock winding and not rewind ? I forgot, but do you use 24 or 48 V system voltage ?

Peter.