After having just recently completed a rewind of a starter motor armature, the best advise I could proffer is
1. "get some other poor slob to do it"
The second best advise I can give is
2.zubbly, patience patience zubbly, and patience.
Third piece of advise is
3. something I learned by doing a big (grader starter motors are big everywhere) commutator, soldering iron is not remotely good enough if the wires you are using are large, however, a Makite 1200w heat gun, AND soldering iron makes a perfect soldering device for doing the commutator connections, if I hadn't discovered this it would not have worked out at all.
The trick is using the soldring iron to heat up the segment as well as it can, and . aim the heat gun onto the segment, and the extra heat from the iron on that particular segment allows that one to melt, not the one next to it. My wires were three inhand 1.8mm (x2) Thats 6x1.8mm wires and the copper commutator all at once, soldering iron had no hope on its own. With airgun- easy as hell. this was the key. The rest is just wave winding the armature. Looks complicated but care and patience will do a good job. be methodical.
Being a high speed motor, there is a better chance that the commutator will have the same no of segments as slots, and this will make it easier to follow. If it has twice the no of commutator segments as slots then see 2. above (sorry zubbly, being good is not all it's cracked up to be.)
For the effort, it will in all probability be more for the want of doing it rather than ending up with a super generator. Brushless is better, but for a project, it may interest you if time is not of the essance, and stubbourn patience abounds.
... Most satisfying when it works... although the wife struggles to get enthused, (yes thats nice dear...... continues peeling the potatoes)
..........oztules
