DIY Alternator - Stator Assembly
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The stator and the main body of the alternator is essentially one and the same. I used a piece of 1.27 cm (1/2") plywood as the base, and a 21 cm (8.27") length of 2X6 as the back of the alternator. Below are the exact specifications.


Adding the the first stator stand and the back board.


This thing needs to be sturdy, so don't be afaid to use serious screws in putting it together.


This is the 1.25" pipe flange that connects the alternator to the tower. Add this before doing much else, becasue once the rotor is in place, it's hard to have access to tighten bolts in the middle of the alternator.


Adding the first part of the stator.


The stator needs to be lined up almost perfectly with the hub. At some point, you'll probably need to throw away the actual specifications to get everything aligned well. I spent a lot of time making sure everything was aligned correctly.


Rotor is attached by drilling a hole through the back board and securing it with this nut. Literally the entire rotor is supported by this, but it works pretty well. For most bike hubs (like this one) you'll need a 9mm nut. But for some bike hubs, it will be a 3/8" nut.


The back stator piece needs to fit around the PVC. If the fit is too tight, file it out so that the PVC pipe can freely spin.


The rotor will half the stator. Make sure this is aligned well!


The two halves of the stator together at last with the rotor.


Complete un-wired alternator. At this point, I still was uing bolts to hold the stator pieces together.


Bolts didn't work well to hold the stator together becasue they were attracted to the magnets, so I switched to wood pieces cut out of .635cm (1/4") plywood that were 10.16cm (4") long and 2cm (.79") wide. These can be seen in all of the pictures past this point.





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