"I checked voltage between each of the 3-phases at the AC side of the rectifier and they are all pretty close, at about 60rpm I measure 44volts between each leg. I have a breaker between the rectifier and the DC distribution box, when opening it I see the voltage starting to climb, but can't observe the blade speed from my basement."
If you open circuit the battery circuit at 13mph I would expect the voltage to at least double and very quickly ( seconds).
"Currently the air gap is about .080" on each side of the stator, between the stator surface and surface of magnets."
Doesn't tell us anything as we don't know the stator thickness, air gap is from magnet to magnet.
"I see the battery voltage rising very slowly and suspect that essentially my wind turbine is not much more than a 'trickle charger', but do not know enough to trouble shoot to much of any degree."
You shouldn't be using battery volts as a charge indicator, for some reason you seem unable to measure amps and you must sort that before doing anything else, you are just guessing without that information. You will not be able to do any worthwhile troubleshooting without measuring current. Measuring wind speed is bad enough and you could be way off on that one, but you must be able to measure current.
By all means go for the new stator, do it now if you like and change it when it is done, but at least learn form your present one otherwise the new one may still not solve your problem.
Fux
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