There's probably not too many people interested in this since it's not in the homebrew plans, and I obviously don't understand how PM generators work. But I figured I'll post it anyway just in case somebody might like to look at it.
I wanted to build a iron stator core tonight but decided I'd better build the rotor completely first so I know what the dimensions have to be for the stator core. This generator will run a .005" air gap so paying attention to the dimensions is critical. This is the rotor for the generator:
It is built using a 2" wide section of 6" Schedule 40 pipe, a Weasler X-1 keyed hub and the center disc torch cut from 1/4" sheet steel. The center disc is welded to the hub and to the inside of the pipe section. The whole assembly was then chucked in the lathe and the ends of the rotor drum faced, and the drum surface machined to 6.500" OD and +/-.001" runout. With the 12 magnets installed on the rotor, the rotor OD will be 7.5". The center disc is welded off-center in the drum because the drum is going to be drilled, and the magnets both JB welded and bolted to the drum. It will use 2 x 1 x .5 N42 bars with holes pre-drilled in the center of the magnet.
This will be a 2 kW capacity unit with a delta winding, 24 volt, driven by a 13 foot PowerMax rotor. The stator will have 18 coils wound on an iron core using AWG 14 wire. This generator will have a 360 degree plastic shroud around it with ducted forced-air cooling using a eight blade fan in the rear that draws air in the front, passing thru the generator, and exhausts it out the rear. It will be mounted on the PTO shaft on the new rear-gen turbine I recently built.
That's the basics of the design - I'll post some more pictures here as I get time to work on it and build the stator and cooling system.