Well managed to cast a stator, using 79 turns of 24 swg. Unfortunately the resin mix was not right, and the casting had not set fully even after a week. I think the catalyst did not get mixed in enough before pouring.
But it has given me the chance to try out some different coils. My initial coils were wound around a trapezoid which on second thoughts is a little bit too big. So I created a new former which is roughly the size of the magnet.
Using this I was able to fit a 180 turn coil in the space I had a 79 turn coil before again using 24 swg, but I was also able to fit an 80 turn coil made from 22 swg as well.
With the 180 turns I was getting 2v spinning by hand - about 270 rpm, and 4.5v using a drill at 540 rpm.
With the 80 turns 22 swg I was getting about about 3v at 540 rpm.
Based on some calculations I estimate that to get 50watts usable power, with the 180 turn coils I would be wasting about 220 watts in heat due to resistance, and only 64watts in the 80 turn 22swg coils.
Next step is to make 8 more of the 22swg coils and try and make the second stator.
