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How To Rewind an Alternator

Step 4Sliding in the New

Sliding in the New
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  • new rewind1.JPG
  • stator prep.jpg
  • new layout1.JPG
  • new layout 2.JPG
  • new rewind 2 closeup.JPG
By the way, I salvaged the enamelled copper wire from an old fridge motor, for what its worth.

In this 3 phase 4 coil wind in 24 stator slots, we start by inserting the 1st coil and skipping 2 slots for the other 2 phases.
Even the start wire (lead in) and the exit wire (lead out) are separated by 2 slots as can be seen in the pics below.

120 degree phase separation mistake.

It has been pointed out to me that my phases haven't been wound with a 120 degree separation, more like 60 degrees, which will most likely result in low voltage output.

I should have left an empty slot between the lead out wires, so a rewind will be necessary to correct this mistake.
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Author:petercd
general bloke type of tinkering