Hi, I've been tryint to build my first dual rotor alternator and keep running into problems just getting started.
I guess I should start at the beginning, I have some 3/4"x1/4" neos prolly n35s that I planned to use in a 12/9 3p alternator.
I started by cutting some thin steel for the rotors with a torch but they twisted all over the place, waste of time.
Then I cut some saw blades to 8.5" diameter and got a friend to weld on some locking collars for the shaft I chose, the saw blades cracked almost immediately, another wasted effort.
So now I'm thinking of going with some 1/4" mild steel plate but before I spend any money on them I have some question in my mind as to diameter to go with, the spacing at 8.5" seemed adequate but was wonding if I go with larger diameter rotors maybe I can use larger coils hoping for better output or go with larger wire or both, but is there a breakover point where the spacing being too large is detrimental to output?
John