Prior to tear down this was a 3/4 hp 3 phase Dayton motor with two burned out phases.
220/440 vac motor, 2 x 210 turns of what looks like 26 awg wire per phase. not too efficient it would appear, so i figured rather than rewind it I'd have some fun with this.
It would appear i can just thread rotor coils in there and use it as a generator and see what i can get the efficiency up to.
Pull the slip rings off of an old alternator and press it onto the shaft, with some kind of custom brush holder made up.
Can't be that hard...
Another option is to machine a .25 inch thick slot through the laminate stack and all the way into the motor shaft, leaving about .25 inch left in the motor shaft. (because the motor shaft shorts out the flux)
This would unfortunately weaken the motor shaft significantly, but i think it would hold up. then, insert (2) .25 inch thick neodymium magnets into the slots.
the laminate stack is a convenient 1.5 inches thick btw.
However, if i try to do that then there's nothing to hold the "pole pieces" onto the shaft, other than the magnets alone.
I'm not sure epoxy can be trusted, not at 3600 rpm anyway, I think i would have to mill a slot in the newly formed pole pieces, cut a bar to fit into the slot, drill holes through the bar, laminate stack, and into the shaft. then thread the shaft and run a bolt down it.
Of course, now that i think about it, if i had not melted the alumimum out of the rotor, i would have been able to cut the slot into the laminate stack, insert the magnet into the stack, leaving the aluminum to hold the rotor together. (tensile strength of .999 Al, anyone ? .. yikes)
For the moment I'm going to try and clean the aluminum out, thread paper down the slots and run about 6 turns of #15 per slot and make 8 coils on each side of the rotor, run them all in series. should get a nice sinusoidal field to it. The Skew of the rotor is a bit steep for a 4 pole conversion, but if this works as well as i think it should, I have more burnt out motors to play with.