Home stator rewind

[Smokinapankake]

So, just to update as I like closure, I did my own rewind and measured somewhere in the vicinity of .7 to .9 ohm resistance among the 3 phases, with infinite resistance between the three and ground. Looks good electrically but not so good visually. I tore the he!! out of my hands doing this and am not 100 percent sure I got the same # winds on each pole. I may be + or - 1 or 2 at the most. At any rate, I got to thinking about it and decided that, since I just wired in a beefmaster CBR R/R and don't really want to cook it, and am a little suspicious of my own handiwork, I ordered a new stator from Electrosport. I'll keep the rewound stator as a backup but for now I have a new stator and new R/R wired in. This should eliminate any charging problems for now and hopefully forever!!

1 pound of 18ga magnet wire cost me all of 12 bucks. This provided ample wire to do the stator and then some.

I did take pictures as promised, but since I'm at work and don't have access to them, I'll post later tonight...
Thanks for all the advice everyone, this has been a learning experience and gets me closer to my motorcycle. This forum is great!

[Nessism]

Great job on the rewind but you are wimping out by not running it. Slam it in and crank up the bike. CRB R/R's are a dime a dozen so give it a go (easy for me to say).

[Smokinapankake]

Ya know, Ness, I had the same thought but what I dont want to do is (admitting ashamedly) redo the whole thing, i.e., find another R/R, take it all apart and wire it all back in, maybe have to get another gasket, etc... The damm bike's been sitting too long already, mornings here are in the mid 50's to low 60's (winter is coming fast), and I just want to be done with it..... Haven't had enough riding time as it is!

[Matchless]

Good job on the rewinding and will appreciate the pictures when you have time.
If the windings were done with the correct rotations and poles and test as you said it should work.
There are so many fried rotors out there that maybe another forum member could test it for you in return for his fried one? It would be worth it to know that your handywork is usefull!
Again well done!

[mixongw]

Seriously. I have had my stator on the bench for almost a month now (many other projects as well) and have not yet found a reasonable supplier of the magnet wire. There were suggestions of asking local shops, but they only have it in bulk spools and want me to pay labor to wind onto spools putting it up to 45$/lb! Another shop told me flat out "For a small amount like that, All I'd do is buy it from McMaster and mark it up double to the public" and this is as I was calling on my factory's account. Online has been more or less a bust for me too, as the windmill hobbyists and the copper market have driven the market wild.

Does anyone have a good source for 2lbs of 17 or 18 AWG winding (magnet) wire?


I'm hoping for around $15/# or less. $30/# or more, plus epoxy, plus shipping, is not worth the effort.

I just ordered 300' of 18 AWG enameled copper from McMaster-Carr for $21.00 and a can of spray high temp sealant for use in motor windings for $7.30.

[Shaughn]

Size Diameter Cross-sectional area Weight
AWG inches cir. mils sq. inches lb/1000 ft

18 --------- 0.04030 ------- 1,624 ------ 0.001276 ----- 4.917

That's the wire weight of 18AWG copper, which means your 300' is
only about 1.639lbs. Which, if I recall correctly, is not enough.
Now, I ended up not needing the rewind upon retesting, so I'm not sure,
and its been a year, so I don't remember the exact math, but you might
want to make sure you have enough wire there to get the job done with one
piece. At the time of that post, I was a project manager for an engineering
firm, and I was ordering from McMaster and MSC and the like daily. I don't
recall why I didn't buy from them, but I think it had to do with the net
cost to get the amount needed vs just getting one from the guys in NH.

Good luck!

[mixongw]

Am I understanding this correctly? 300' is not enough?

[gearhead13]

BTW I have a brand new high performance stator for sale in the sale section A LOT cheaper than oem, even cheaper than what they wanted for a used one at the salvage yard.

[mixongw]

I just did a rough calc on wire and it breaks down like this:

2" of wire per turn * 35 turns + 6" for start and end splicing = 76"

18 poles * 76 = 1,368" / 12 = 114' of wire needed.

Did I miss anything? Ok guys... Tear this apart. Go ahead. It won't hurt my feelings.

[POE_333]

has anyone considered or tried using a smaller GA wire then typical, but using two thinner strands to wind the stators instead of one thicker GA strand? I'd think that maybe you could pick up a lil extra current without picking up extra voltage. Any thoughts?

[Steve]

has anyone considered or tried using a smaller GA wire then typical, but using two thinner strands to wind the stators instead of one thicker GA strand? I'd think that maybe you could pick up a lil extra current without picking up extra voltage. Any thoughts?

My thoughts are that thinner wire will allow more turns, giving you more voltage. However, you did say you would be running multiple wires in parallel, cutting the voltage and adding a bit of current. Not sure how the additional current would compare to simply using larger wire, though.

I am going to try rewinding a couple stators, one using 18ga wire, the other using 17 ga wire to see what the difference is. I expect that the one with the 17ga wire will not charge until the engine is at a slightly higher RPM, but I will be using an FET regulator, which charges a little better at lower RPM, so it might balance out.

.

[rustybronco]

I am going to try rewinding a couple stators, one using 18ga wire, the other using 17 ga wire to see what the difference is. I expect that the one with the 17ga wire will not charge until the engine is at a slightly higher RPM, but I will be using an FET regulator, which charges a little better at lower RPM, so it might balance out.

.

It looks like you and I are doing parallel projects.

(received the old dud stator from Mr. Basscliff, Thanks much !!!)

[Matchless]

I think once you actually wire one you will realise that winding two wires at the same time by hand is going to be very hard to do. I think that is why no-one has done it.

If you are planning to rewire your own send me a PM if you want a copy of the guide I wrote up when doing mine. In actual fact I now have two unusable spare iron stator frames left and only got it done properly 3rd time around. The actual rewinding of the copper is really the least of you problems. Using the correct enamelled copper and resin/epoxy and preparation of the stator is the most important part if you want to have it last a while in a hot oil bath.

[posplayr]

I think once you actually wire one you will realise that winding two wires at the same time by hand is going to be very hard to do. I think that is why no-one has done it.

If you are planning to rewire your own send me a PM if you want a copy of the guide I wrote up when doing mine. In actual fact I now have two unusable spare iron stator frames left and only got it done properly 3rd time around. The actual rewinding of the copper is really the least of you problems. Using the correct enamelled copper and resin/epoxy and preparation of the stator is the most important part if you want to have it last a while in a hot oil bath.

Voice of experience

[Matchless]

Voice of experience

I slightly underestimated the job first time around and as you guys say "Don't ask me how I know"