Thanks for the inquiry and I'm glad to see there's another proponent for the non-cast stator out there.

When I initially proposed that stator resin casting was contra-indicated, I thought there would be wide acceptance of the idea since the arguments were so obvious. I guess I grossly overestimated the acumen of the following of the Hugh/DanB design - seems almost cult-like.

I haven't tried to promote a particular alternative design, only that there ARE other alternatives without the disadvantages.

Even with the almost continuous stream of reports of stator failure, particularly for larger machines, the great majority of new construction reported here continue to use cast stators. Go figure.

My 16' machine progress has taken a somewhat different turn since I wrote Parts 1 and 2. Some thought there was an issue with unbalanced strand currents in layer-wound, multiple in-hand coils, resulting in circulating currents and increased losses. I decided this was worth investigating, so the order of construction was modified.

To test the circulating current hypothesis, it would be necessary to complete the magnet rotors and rig a test setup before completing the stator. Better to determine if this problem exists to a substantial degree, with my actual coils, before committing the remainder of the expensive square wire.

I suppose I should apologize to those who are interested, for the lack of continuity on this project.  Acqusition of materials for the rotors and ill health for a while, prevented very much progress. Never fear, it will go on (as long as I last).

I took advantage of this period of infirmity to put on my electronics hat and designed circuits and PC boards for numerous (8) projects that have long gone wanting.