4 test stators cast.

[Jerry]

Thank you to the person that sugjested the toilet wax as a release ajent.

I casted 4 test stators yesterday and I've been worrying about the release but the forms came off prety easy today.  

Here is one still on one side of the form.

Here are all 4 after they came out. The red looking ones are the 24 gage. The others are the 18 gage.

I'll clean them up befor the final assembly.

                           JK TAS Jerry

[s4w2099]

Man, They look really nice. I am eager to see the results.

[harrie]

Hey Jerry, looks great. I would think the way you made them, would provide much better cooling also. does the center plug get removed?? Thanks for sharing.

[coldspot]

JERRY-

I think the jerry-phased would be best for power in most gen's.

But,

I don't see how the round and oval coils could be used on same rotors?

Looks like the ovals would miss the magnets if the magnets are centered over center of round ones?

[tecker]

I like the fiber glass . Does the casting hold the coils firmly.

[Jerry]

Hi coldspot.

These 4 stators are for 2 diferant alts. One uses 1.5" disc NEOs the other uses 1"X1/2"X.25" NEOs.

So 2 stators for one machine and 2 stators for the other machine. I'm also building 2 more alts with 2 stators each. For 4 more stators.

Then on to the heat,load, open volts, output power at driven power and ect.

                            JK TAS Jerry

[richhagen]

You mounted the coils into wooden supports?  That seems like a good way to cut down on the amount of resin required.  especially for test stators.  Rich

[Jerry]

Hi Rich.

I use fiberglass sheeting. Its about 1/16" thick. Its used for makeing shower stalls. One side is smooth with a flate or dull finish. The other side is glosy but with a textured finish.

I use a router circle cutter and cut out rounds. I stack these up and glue them together after I have the desired stator thickness.

Since the are allready fiberglass they end up very strong. I cut holes for the coils to drop into. I drill small holes through the sides to let the coil leads out. I place the coils in the holes and then pour the reson over, in and around the coils.

I have a bottom board in place when I do this. Then I place the top board on and bolt it all up tight, let the reson set up then remove the top and bottom boards.

WALA a stator.

                          JK TAS Jerry

[richhagen]

OK, I had seen the lines on the side and thought it looked like plywood.  It kind of reminded me of the stator from Hiker's saw blade mill.  It looks like a pretty efficient way of doing it, since your cutting the holes for the coils, it pretty much guarantees it will line up right, and the fiberglass sould be pretty much impervious to the weather as well.  Rich