hi flux and thanks for the comments.
now i have had time to digest what you said.
as i am only learning slowly then i went bye the book when it came
to potting the rotor.
only adding small vanes.
but from what you said about about air from the magnets . if not potted
sounds a good idea.
so now i understand i can make a compromise and only half pot the mags.
still cover them with glass matt.
so i will just half fill the rotor mould this time.
no lid and just stipple the matting with a brush.
it wont be a perfect finish but will move plenty of air.
but i will make sure the brush has a stainless steel metal band.
if need be i can do a bit of sanding to get a better look.
i suppose in a way this is a short cut.
but now i understand a lot more .this will save resin and provide a good airflow.
magnets will still be covered as well.
and saves all that messing i was trying to do with the vanes.
as you have said in the past its knowing where you can take short cuts.
as this is small 9" rotors i am using here i cant drill holes near the center
as is done on the larger gens of the rotor to help with air flow.
as far as filling the winding space with copper
then i still need to ask for advise on that.
but i understand now what you mean .get as much copper as will allow with the same amount of turns. just make the dia thicker.
when i first started to wind test coils i was surprised as to how small thay
looked. against others i saw on here.
putting then on the scale i new thay were to light in weight.
i almost have that problem sorted out .
but of course if i put to many turns of wire it will lower my cut in speed and go into stall.
as my real love is working in wood i find trying to make electric at home
a real challenge .
but getting a lot of understanding here on this forum .
i have one book written by hugh and looks like i can invest in a new one soon.
he has a new book out. great just what i need.
but i am still going to make holes in my stator. thanks flux.
its a ill wind that dos no good
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