Not sure about the machine details, I assume it is 10ft, does it have the rectangular magnets.
One thing is very obvious from your pictures, you have only wound about half the available space. You could just about have doubled the wire size and made the coils bigger so that they touched on the outside, this would probably have reduced your resistance to 1/3.
You are probably right about too many turns and too low a cut in speed. That would have given you the option of getting below 1/3 of the present value and that would have cut stator losses by 3.
If it is 10ft and they are rectangular magnets then I agree with others that 16 magnets is a better option but if you reduce your winding resistance you should get the 1kW into a mppt inverter ( not for direct battery charging).
When you get it to furl it will drop power as it goes hard into furl and the prop will be virtually edge on to the wind. I strongly suspect that didn't furl at all.
These windings may handle 1kw peak during gusts but not 1kW sustained for long periods.
On a bench test I suspect your winding with only half size coils would struggle to hold 400W.
If you had the inverter programmed correctly the thing should be running well clear of stall. If you used the original furling for stalled battery charging it would not furl at any sensible speed if at all. I suspect you have to increase the offset a bit anyway to get it furling and you will need to reduce the hinge angle or make a much lighter tail.
It looks from the pictures as though the wire is cooked but it might not be, I don't know what temperature superglue will stand but it may have disintegrated below a temperature that would damage the wire coating and expanded the coils.
I have never found a use for superglue, I tried to stick fingers together and it failed there as well. I would never put it near a winding. If the temperature was high enough to fry the wire coating then the superglue may not have been a major factor.
Polyester will not stand the limiting wire temperature long term but it will probably stand it for wind duty for several years. Vinyl is better and there are a few epoxies that are just as good but normal epoxy will not do as well as polyester.
My immediate thought is to reduce turns, use the thickest wire that will get the coils in the space and you could squeeze the holes a bit more triangular if needed.
Wet wind the coils with vinyl or high temperature epoxy and make it furl so that it drops power in very high winds and I think you can get the 1kW.
Thanks for posting the pictures, a description alone would not have let me realise how much you could have reduced the resistance but using more wire.
Flux
