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#Post#: 3063--------------------------------------------------
Re: Seagull 175 Alternator
By: nessprojects Date: June 1, 2014, 7:44 am
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@cg
I have a problem downloading the pdf files.....First click says
unable to download but I then hit retry and it downloads and
opens fine. It registers as downloaded twice but I only get it
once. Do you have the latest pdf reader.
Adobe pdf reader works fine for me.
@Lynx
Circuit good now....Only nit-picking now but under radio shack
parts you only have 2 diodes but I think everyone will get the
point.
#Post#: 3064--------------------------------------------------
Re: Seagull 175 Alternator
By: lynx wind Date: June 1, 2014, 7:56 am
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Thanks Ness for proofing stuff. Changes made. I will make one
of these for Happy and hope to contain it all on the Bridge
rectifier's footprint.
I'm off to wind coils and cast a stator before family gets up.
People wonder how I do so much. There is a lot more spare time
than you think. TV, entertainment, drinking dull the senses and
we lose our creativity. Nothing wrong with that, I may do a
little of that later.
#Post#: 3065--------------------------------------------------
Re: Seagull 175 Alternator
By: lynx wind Date: June 1, 2014, 11:59 am
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I'm getting better at this. Took me about an hour for this alt.
Helps to have all the jigs, molds and supplies ready. I'll
take it out of the mold tomorrow. The 1/2" thick urethane cast
is so strong you can smack with a hammer and it wont break.
The resistance came out really low.
Parallel 100 turns (15 awg equiv) 1.25 Ohms for 12 volts
Series 200 turns 18 awg 5.0 Ohms for 24 volts
Picture 1 coils wound and wires cleaned with torch and steel
wool
Picture 2 coils ends continuity checked and 1 set ohm'ed
Picture 3 both coils put in parallel and ohm'ed
#Post#: 3066--------------------------------------------------
Re: Seagull 175 Alternator
By: lynx wind Date: June 1, 2014, 12:00 pm
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Picture 4 brass connectors in place, all wiring tucked and
coils centered - ready to mix and pour
Picture 5 Urethane poured and ready for top plate of mold and
300 lb press
#Post#: 3067--------------------------------------------------
Re: Seagull 175 Alternator
By: nessprojects Date: June 1, 2014, 2:50 pm
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Resistances look really good.....Cannot wait to see the final
voltage checks.....Very good.
#Post#: 3069--------------------------------------------------
Re: Seagull 175 Alternator
By: lynx wind Date: June 1, 2014, 3:21 pm
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I used epoxy for a long time but it's expensive and takes a long
time to cure. I tried Urethane and it flows like water and sets
quickly. I use the slow cure from Smooth-On. I can pop a
stator out every two hours. The demo stator you may have seen
was epoxy so people can see the coils. The Gulls all use black
Onyx Urethane.
The first time I used it I mixed too much and it started getting
hot. I threw a glob on a board in case it caught fire. I
wanted my board back so I figured I would just whack it off with
a hammer. Uh,.... no this stuff doesn't break or shatter.
Something about its matrix makes it very tough. It machines
well, sands well but doesn't crack like epoxy.
It also comes out shiny when cast in a smooth mold.
#Post#: 3071--------------------------------------------------
Re: Seagull 175 Alternator
By: happygolucky Date: June 1, 2014, 4:37 pm
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#1 stator for 175 kit nice tutorial @lynx winds..... i have
been comparing all your notes an studying your calculations
from my charts an study in theory , low resistance numbers are
very good indeed for the 2 in hand. coil stator . like @ness
said cant wait to see the final voltage ...i did study your
boost lynx rectifier too @ ness....urethane is good stuff hard
as a rock..i have seen others use it..an beat it with a hammer..
maybe i should re-vist that idea for the mold.. now the magnets
where .375 an coil winding .75 approx. after press an urethane
should be .50-.625 thick. after pressed is the stator a 10" or
12" diameter what did you settle on .. just thinking out loud
them magnets do make a difference. too
#Post#: 3074--------------------------------------------------
Re: Seagull 175 Alternator
By: lynx wind Date: June 1, 2014, 5:27 pm
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The stator ended up being 11.25" diameter. No need to waste
material. The stator is precisely 1/2" thick and the gap will
be 1/16". It can be up to 3/32" for a bit of play with no harm.
This will be a fun alternator to play with. Running through a
transformer for 120 vac, changing the wiring etc.... So far so
good. I was looking at some comprable alts that put out 450
watts at 450 rpm. I am crossing my fingers that this is going
to be sweet.
My press is very hillbilly right now and I wont tell you how it
works. I need to refine that when I get time. Really the coils
don't need a lot of crunch, they are 7/16" thick. It's more to
get a slick smooth surface.
#Post#: 3077--------------------------------------------------
Re: Seagull 175 Alternator
By: happygolucky Date: June 1, 2014, 5:58 pm
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@ lynx got it the voids/ bubbles should be null free with
urethane's lack of viscosity.. ..i understand.. thanks i was
just curious of the over all dimensions..
#Post#: 3078--------------------------------------------------
Re: Seagull 175 Alternator
By: happygolucky Date: June 1, 2014, 6:18 pm
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you bet @otis it is fun...to hang ten on a kite..wish i could do
it again maybe? i'm not much of a risk taker anymore my - karma
keeps going up! we had a great karma day so spiritual a healing
was awesome..i was fly high... brought back memories..
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