This rotor is out of a 5.5hp 6 pole single phase motor. I cut it down far enough to hold 6 full size magnets they are 2x3 by 1 inch thick the other pieces are the same type blocks cut in half. The rotor is round there are no flat surfaces under the magnets just lots of JB weld.
Next I filled the gaps with fiberglass resin with a piece of fiberglass rod in the gap for extra strength and finished grinding the magnets down with my Dewalt grinder and the 4 inch Planet diamond tile saw blade.
After this I coated the whole thing with Gorilla glue and wrapped on 2 layers of Kevlar ribbon and 2 layers of cotton thread to hold everything down tight as the glue started to expand. As it expanded I worked it back into the kevlar and cotton fibers. It came out looking better than I expected. The magnetic feild isn't bad either it will grab anything metallic within 1-1/2 to 2 inches away.
I hope to test the completed genny in a week or so and post some results RobC
