I started this project over a year and a half ago, and finally decided to raise it in the city to test it while here..
Parts list
-1 roll #14 awg- coils were 2 strands #14 33 turns each, 12 coils 3 phase
-magnets dual rotor 16 magnets per plate
-plates- dual rotor 14" diameter each x .250 thick
-magnets- 1"x1" diameter neos, 16 per plate 32 total
- stator is 1/2" thick and 16" diameter.
-bracket and tail were to hugh piggots book design
-blades were 8' diameter to hughs design
-tower was 23' high of 2" diameter pipe(i would suggest larger
Made a paper template of the stator and coil placement..also made 2 test coild and found that 33 turns of #14 wire(2 strands, fit nicely with the 12 coil setup
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I then putall 12 coils in the stator and trimmed them to the right length, butned the ends with a torch, soldered them up,andcovered them with heat shrink
I then put the magnets on one plate, making sure to alter north south, north south...make sure you mark both plates while the holes are alignedso the magnets will be in the right position in reference to one another
I then made a makeshift mold around the plate for puring fiberglass..this is just a precautionary measure so the centfifgul force wont throw the magnets off the plate while spinning...some just use durabond 2ooo or some other kind of adhesive, and i am sure it will work well also..you also see the stator mold being in the cool down stage
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below is what the plate with the magnets looks like after the resin has dried..you will use about 1 quart...i have found it is cheaper to buy 4 quarts of resin, than it is to buy a gallon can, and it is easier to use a quart at a time too
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now you see the stator being removed from the mold
I then mounted the stator on the spindle
I like to hook an ordianry plug to my exit wires as it is easy to unplug the genny if i need to do some work at a later date..each prong carries 1 phase down the tower
here is a picture of hughs blade root for those who havent seen it
here is a close up of three 25 amp bridge rectifiers...i use 1 per phase...i think maybe i should have gone a little higher with the size, but time will tell..i put dielectric grease under the rectifiers to the aluminum heat sink
the last 2 pictures of the mill flying...very satisfying seeing the end result...there wasnt much wind today, and it was in spurts but i seen at least 120 watts, i suspect it will make at leat 3 timesthat for sure with a decent wind
hope this helped a few new guys... pickster
