This will cover rewinding of an alternator stator for use in a wind turbine generator.
Traditionally, the use of car alternators is discouraged in favor of homemade slow running axial flux generators. However I bought a small Hitachi alternator for 1/3 of the price of one rare earth N35 Neodymium magnet, typically one uses 24 of these magnets in a wind turbine, so it would take about 45yrs to recoup the costs of the magnets alone.
In other words, not gonna happen.
Im using a Hitachi alternator from an early 1970's 1200 Datsun that had an external regulator mounted on the fender in the engine bay.
I figured this being my first foray into alternator rewinding, it would be much easier learning on a simple little 35Amp alternator like this. The downside is the rather low output and I probably wont go to all the trouble of mounting it on a pole too.
Be that as it may, it serves as an example of how alternator rewinding is done, whether it is just repairing for auto use, or modding for windmill use.
Step 1: Pull It Apart
This is relatively simple, 3 long bolts and the case is apart.
Then remove the field connection brushes from the rear of the case, it has the letters F and N on the connector, being field and neutral.
Once everything is apart, check the bearings for wear, they should turn freely without noise of grinding. They shouldn't spin which would indicate that they are dry.