Motor /Generator Stator Casting Mold (7.75" diameter with 12 slots) by Cotton80

Last crawled date: 3 years ago

This is an experimental stator casting mold process. The outer diameter is 7.75". The inner diameter is 4.0625". The depth is 2.125". This is for the more advanced tinkerer. It represents an effective alternative to silicone steel or metglas/ceramic type stators for the home inventor/builder. There are many magnet and wiring arrangements that one can experiment with. You design your own motor/generator housing, bearing holders, and wire scheme/circuit. Telsagenx has some basic circuits for running pulse motors/energizers and energy recovery circuits if that is a direction you would like to go with this. Follow this project at : http://www.energyscienceforum.com/showthread.php?t=3848
A video to explain the process for steel shot preparation and to give credit to the individual(s) who originally came up with the idea to use coated steel shot: https://www.youtube.com/watch?v=kpHEyzvc4dY
Disclaimer: Experiment at your own risk. The end product (actual stator) has not been thoroughly tested for heat dissipation, load testing, or reliability. Sourced products that I have used in the completion of my stator have been outside of the manufactures recommendations. This represents what worked for me. You may not have the same results.
There is an optional rotor file for a generator or pulse motor. The magnet size is 2" X 1/2" X 1/8". The shaft size is 3/4". The set screw size is 1/8".
Video instruction: https://www.youtube.com/watch?v=LzC5SP4e_uAhttps://www.youtube.com/watch?v=aPIIT2ObSvchttps://www.youtube.com/watch?v=3uz2U-aGob4
07/08/2017 at 14:32 est: added sample motor end/ bearing holders
I completed the file for sample motor end/ bearing holders. This is what I will use on mine. It is for 3/4" X 1 5/8" X 7/16" bearings. The inner bolts are 6-32 X 3/4" and the outer holes will be for 1/8" threaded rod to connect both sides. There will be an inch of room on both sides of the stator for wire to stick out. Pictures are included here. You will need to print or have printed (2) bearing holders and (8) legs (4) for each side.
08/11/2017: added new bearing legs that hold the stator in the middle. (takes 1/4" X 5" bolts)
added a 9-piece rotor for people with small printer beds. (takes M4-.70 X 60 bolts..4 of them)
added stator end caps to hold the wire back..Just glue them on with Gorilla glue