My altanator/ stator/ generator...what do I have here?

[basketcase]

Have you yet checked to make-sure the stator-cavity IDs are the same for both rotors ?

Just checked them, yes they are the same.

[DewCatTea-Bob]

I have read some of the threads on hear about changing the wiring to accomplish this, But they are lengthy and go into alot of theory, and use terms that I have heard, but am not familiar with.
I am quite capable of soldering and wiring......but there would have to be step by step directions with diagrams for me to accomplish this. If there is a thread already here like this, please let me know.
Thanks for all your responses Bob.

____ Sorry for taking so long to get back to this !



" I have read some of the threads on hear about changing the wiring to accomplish this, But they are lengthy and go into alot of theory, and use terms that I have heard, but am not familiar with. "

____ No need for much concern, as I'm willing to walk you through the process,, and if I go-past any detail which you require further drawn-out explaination of, then just let it be known to me.



" I am quite capable of soldering and wiring. "

____ Very-good, as that should be quite sufficient talent/ability to accomplish all that which needs to be done.



" but there would have to be step by step directions with diagrams for me to accomplish this. "

____ Step-by-step instructions should-not be any issue, however "diagrams" may not be available for whatever your particular detail.



" If there is a thread already here like this, please let me know. "

____ There are already a number of other related threads, at least a couple of which have gone-down the path which you probably ought to follow, as well. _ However finding those particular thread-postings of most direct interest to your alternator-project, is overwhelmingly taskful,, as our w.site's search-engine always seems to either find nothing at all OR-else finds hundreds-of-tons of thread-posts with an overly high percentage of non-directly related topic-matter !
__ I know it wasn't too awfully long ago that another fellow did the alt.stator modification (and had added 1-pair of 18ga & 1-pair of 16ga wire-leads [almostly] as I had directed), but I can't think of his name, and-so was hoping that he would notice this thread & chime-in.



" Just checked them, yes they are the same. "

____ But you haven't yet mentioned how well your two rotors stack-up as far as their magnetic-strength goes. ...
If the brass-rotor's magnitizym isn't notably weaker than that of your alum.rotor, then I'd suggest choosing it (for your project).


____ Can you post a close-up pic.view of your alt.stator ?


Hopeful-Cheers,
-Bob

[basketcase]

The magnetism of the flywheels was about equal. (I used the fridge in the basement so that the warden didn't get angry .

I'm struggling to get a clear, no glare, closeup of my stator. Hope this one works. If you need better let me know and i will try some more.

[DewCatTea-Bob]

" The magnetism of the flywheels was about equal. "

____ In that case, I'd suggest using the brass-rotor.



" If you need better let me know and i will try some more. "

____ Despite being an excessively large pic, it doesn't reveal very clear detail,, however that's okay, as we only needed to see it well enough to be sure of exactly what we're going to be working with.
When the possible need for showing your particular unit arises, then you may try posting a clearer picture of what you have. _ But for the mean-time, I can post a clear-pic of another stator-unit. _ Hopefully you'll find it same as your-own unit well enough to follow-along with.
____ As can be seen on the right-side, there are two separate terminal posting-eye locations, (one each) for terminal-posting of the stock twin wire-leads -(the pair of yellow-wires from the stock black-conduit alt.cable),, at which points, the two separate stator-winding lead-ends are also soldered.
And also, nearer to the upper-left-center area (of the stator-core), can be seen the opposite-ends (of each of the two separate stator-winding lead-ends), which are soldered together to a single/common grounded terminal-point.
All three solder-point locations will need to be unsoldered-apart, since each of the two pairs of stator-winding lead-ends will each separately need to be individually connected to their very-own dedicated wire-lead, (four separate connections in-all).
__ Do you have a source for a single wire-loom/cable with four separate wire-leads contained within ?
If not, I'd suggest an appliance-store ought to carry such an electrical-cable that's intended for a 220-volt electric-drier, which would contain four 14ga wire-leads (colored: black; red; white; green). _ However I-myself always preferred to construct my own custom alt.cable with 16ga wires with colors of my very-own choosing.
(Most always in the past, at this point somebody usually chimes-in with their-own recommended replacement cable option,, and while that's certainly not unwelcome, there is some added satisfaction in actually CREATING your very-own custom alt.cable. _ I've already told of the specific-details of my-own custom-cable in a past thread-post on this subject, so I won't go-into that again unless you desire some ideas on the matter.)
__ What related details would you prefer to specifically cover next ?


Fun-Cheers,
-Bob

[basketcase]

I will use the brass rotor.

My Stator looks just like your stator, so no problem there.

My buddy works in the traffic signal industry and is going to bring some wire home for me. Its high temp, Teflon jacket, oil resistant, 14guage, silver tinned wire in 4 different colors.

I see where the yellow wires are soldered, and I see where the 2 bare wires are soldered to the ground. I will un-solder them.
What next?

[DewCatTea-Bob]

" My Stator looks just like your stator, "

____ Actually, the stator-pic I posted was saved from another member's thread-post, (as it was fairly-well done, and IT happens to be a rare-example without the MORE-common YELLOW-alt.wire-leads).



" Its high temp, Teflon jacket, oil resistant, 14guage, silver tinned wire in 4 different colors. "

____ Such wire should be of high enough quality for the job but, it may be too fat to fit as the stock alt.cable does. _ However if fitment is not an issue, then it will save you the step of creating a replacement alt.cable with wires of preferred colors & adequate gauge-size.



" I see where the yellow wires are soldered, and I see where the 2 bare wires are soldered to the ground. "

____ Even-so, I'm posting a couple pix showing those solder-connections closer-up.
(Others who may one-day wish to do the same alt.stator wiring-mods, may wish to download the pix to save for easier reference in the future.)



" What next? "

____ It would be orderly to learn what colors are the 4 wires within the wire-cable you're sure you're going to use for the job (so that some reasonable-logic can be pre-applied for the connection-installation).
__ While the two separate upper & lower solder-terminals make for rather convenient & relatively easy re-soldering connections,, the opposite-point where the two (separate!) stator-winding lead-ends are both terminated together (to the grounded stator-core), must be handled with extra-care however. _ So handling of those two rather delicate lead-ends ought-to be kept to a minimum, (so best not to unsolder them until you're prepared to go-ahead & also RE-connect each of them to their-own intended dedicated wire-leads).
When THAT pair of lead-ends are un-soldered,, they will then not only NEED to be kept insulated from 'Ground', but also (to somewhat lesser importance), should be kept insulated from each-other as well !
So you ought to then have a fair selection of good-quality heat-shrink insulation-tubing.


Tillater,
-Bob

[basketcase]

____ It would be orderly to learn what colors are the 4 wires within the wire-cable you're sure you're going to use for the job (so that some reasonable-logic can be pre-applied for the connection-installation).
So you ought to then have a fair selection of good-quality heat-shrink insulation-tubing.

When I have the wire's in my hand, i will let you know the colors. They are single strand wires, not a cable of 4 wires.
I am out of shrink tubing, so I will stop by Fastenal and pick up some more. Is there any more supplies that I will be needing? I have rosin core solder and paste flux.

[DewCatTea-Bob]

" When I have the wire's in my hand, i will let you know the colors. "

____ Be sure to first check to make-sure your selected wire-cable can be suitably fitted through/within the motor-casing cable-passageways.



" They are single strand wires, not a cable of 4 wires. "

____ Alright-then, it now seems we should get more detailed with what's actually what at this point...
__ I now understand that you're not actually getting a wire-cable with four independently-colored wire-conductors housed within a common-conduit/jacket-sleeve. _ But rather just a few individual lengths of conductor-wires with colored-insulation (in four separate colors). _ Is that now correct ?
__ In any case, the conductor-wiring which you choose should-NOT be of a SINGLE-strand type, but rather a MULTI-strand type,, and with the FINER-stranded type being most preferable. _ In-other-words, the more individual-strands within a given wire-gauge,, the more desirable then, is the wire for this job ! _ (The stock-wires barely have a sufficient quantity of individual wire-strands within them, cuz their contained strands are too thick & not fine enough [for best longevity].)
Wiring which only contains merely-just a SINGLE/thick-strand (like that of rather cheap house-wiring), is to be especially avoided !
__ So NOW, I gather that you intend to construct your-own alt.cable,, is that your actual intention ?
If so, do you then also have a source for a jacket-sleeve/cable-conduit to route-house your four separate colored wire-leads ?



" Is there any more supplies that I will be needing? "

____ Well, while silver-solder may-not be suitably required for this job, I would choose to use a solder-blend which contains less lead, if available.


Until-Later,
-Bob

[basketcase]

"Be sure to first check to make-sure your selected wire-cable can be suitably fitted through/within the motor-casing cable-passageways.
-Bob

I will do that.

"
__ I now understand that you're not actually getting a wire-cable with four independently-colored wire-conductors housed within a common-conduit/jacket-sleeve. _ But rather just a few individual lengths of conductor-wires with colored-insulation (in four separate colors). _ Is that now correct ?
-Bob

Yes

In any case, the conductor-wiring which you choose should-NOT be of a SINGLE-strand type, but rather a MULTI-strand type,, and with the FINER-stranded type being most preferable.

I guess my terminology was incorrect. They are multistrand wire.
They are 4 individual, insulated wires. They are not contained inside a molded cable or conduit.

So NOW, I gather that you intend to construct your-own alt.cable,, is that your actual intention ?
If so, do you then also have a source for a jacket-sleeve/cable-conduit to route-house your four separate colored wire-leads ? -Bob

Yes, I want to make my own cable.
I dont have any conduit, do you have a suggestion?

Well, while silver-solder may-not be suitably required for this job, I would choose to use a solder-blend which contains less lead, if available. -Bob

I have some silver solder left over from a air conditioning project. Will that work?

Hey, I finally figured out how to multi quote!!

[basketcase]

I found this for conduit/loom/sheathing:
http://www.economycycle.com/servlet/the ... PVC/Detail