Source for rubber biscuit for stator wires

[koolaid_kid]

Not production in that I want to make 2000 and sell them.
But if I make 1 circle, which should make 2 grommets, why not double it up and give me twice the stash?
Also, there will be some loss. If this was a production line, I might assume a 90% yield. With a new, homemade, hand process, I will be lucky to break a 50% yield. So if I need 2 grommets, I need to make 2 circles to insure that I meet my needs.

I purchased 2 grommets from Rick's from information in this thread and paid $5 each. It is a high-quality piece that should fit the factoy 18 gauge wire perfectly.
However, I am going to have to modify them to fit my 16 gauge wire. If I make my own I can design them from the start for the 16 gauge wire I am using.
Hope this makes sense.

 

[koolaid_kid]

Pulled the grommets out this morning. They are not half-circles, so that idea is out. They have a radius, but then are a bit longer than just a half-circle. Perhaps modeling clay? This is a low-budget thing and I may only make a couple, so the on-line rubber mats I have seen exceed the budget. There is one of those art stores nearby, I wonder if they would have an idea of a suitable mold-making material that would not break the bank.
AFA the total quantity, I have 6 stators, but 2 of the cores are damaged and may not be rebuildable. The other 4 have not been unwound, so IDK if they are damaged either.

 

[koolaid_kid]

For the holes, you can heat a nail with a torch (hold with a pair of pliers) and then push it through the grommet.

It's helpful to have the grommet on a piece of wood or metal with the hole you are making over a slightly larger hole in the wood- sort of like you would if you were drilling it in a drill press.

- JC

PS- You might try a male bullet connector on the end of your wire to force it through the grommet hole, then you can clip it off after pulling the wire through.

Thanks, I like the nail idea, I'll give that a try.
AFA threading the wire, I'll have to see. The high-temp wire has a cloth-like external wrap, but then there is an internal insulator that is real hard plastic. With a little something to ease the way (I would normally use the word "lube" but it might be misconstrued ) it should slip through.
The project has been tabled during the inclement weather. I do the epoxying and curing in my unheated garage, and it is current too cool to set either the epoxy or silicone. :|

 

[koolaid_kid]

Update

Update

I took the first Rick's grommet and drilled it out using my Dremel tool and a bit from my $5 HF dremel kit. Angle cut the wires so the insulation could slip through the hole, lubricated with marine grease. Success! Onward and upward.