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Proper Copper Shopper (so I don't come a cropper)

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Andy from the cross:
Hi folks :)
I'm about to splurge on some copper wire and looking for some advice before I order.
The plan is to run a small engine on methane to turn the dual-rotor, 12 pole 9 coil PMA at something like 900 rpm.
Magnets are N52 50*25*10mm, and sketched out as a 350mm dia rotor would indicate the maximum coil size is 120*100mm (100mm across the 40° arc).

A couple of designs i've seen have used 1.6mm wire in the coils, would that be appropriate in this build? Each phase will be rectified separately and combined into an inverter.

Your thoughts, suggestions etc are appreciated. Thanks in advance :)

joestue:
how much shaft hp are you expecting to get?

at 900 rpm a motor conversion would make a lot more sense. also don't throw out winding a synchronous motor from an induction motor. if you can find an angle grinder you can cut the slots in the core needed to fit the coils.

electrondady1:
@900 rpm on a drive motor you could drive an automobile alternator.
in a dual rotor you would need to take measures to secure your mags in place at that speed.
you can do a test coil with fine wire to determine the number of turns  you want to get the voltage you want at that speed. then the challenge is to fit that many turns of fat wire into the available space

 can you describe your methane source and how you feed the engine ?

Andy from the cross:
Okay, 900rpm is guesswork for now, i'm still looking for a suitable motor - a propane forklift engine would be ideal. Let's call that a maximum speed...

I could use alternators or induction motors, but i'd rather create something from scratch.
Anyway, i'm just thinking ahead (or getting ahead of myself...), I have got me some rotors to build.

electrondady1:
do you have your rotors and magnets already?
if so, check out dan b's posts were they band the edge of the rotors.
another popular method is to drill and insert steel pins along the edge of the rotors to keep the mags in place.
most of the alternators built on this page are for wind mills that turn significantly less than 900 rpm.
some mags come with counter sunk mounting holes.

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