Here is some of the pieces and parts of my Alternator.
This alternator was based on Hugh Piggott's Design.
there are a few thing I will do different next time I build another wind Genny but for now it will work.
Many of the parts were made of what ever I had lying around. it is a lot funner to scrounge for stuff I think. It expands the experience.
This is a basic view of the Alternator and Pivot with a furling system
This is the coils in the stator mold. it is a 3 phase alternator. this only one of the phases it is wired in series. 3 in hand 36 turns of 18 g. magnet wire.
The coils are soldered together and then a copper crimp is crimped on to add better conductivity.
Then heat shrink is added to prevent a short
Here in this photo you see all the 9 coils. 3 sets of 3 as you already noticed the coils also have fiberglass Matt below them and small pieces of scrap fiberglass super glued to the coils, this is to prevent them from moving while in the mould when it comes time to pour the fiberglass resin into the mould.
Then all the coils are remove from the mould. In this next step we need to prepare the mould for casting the stator. In this photo we are applying a heavy layer of wax to the mould to prevent the resin from sticking to to mould when it comes time to remove the finished stator. then we apply a layer or PVA over the wax. I don't know what PVA stands for but it is almost like a liquid plastic that will dry and peel off very easy.
Then we carefully place the coils back into the mould and pour the resin into the mould.
I don't have photos of the lid to the mould , but it is just a piece of plywood that is also waxed and PVA.
then the lid was clamped down with clamps and a few hundred pounds of steel. you don't need all the steel but it cant hurt.
after 2 hrs or so we removed all the clamps and steel and this is what we ended up with.
Now i know there are some steps that the photos do not show due to I simply do not have them.
but here are the things left out fiberglass is on both sides of the coils the photos do not show the top piece of glass.
the mould was made of a sheet of PVC you can use A good quality piece of 3/4" plywood instead.
