All three phases are individually wired. All that is left is to cut the loose starts to length, remove the insulation & connect them all together in star configuration…

Three Phases ready to connect in star

So let’s do it:

Soldering the Star connection

The three phases are wired together:

Three Phases Wired

I could’ve cut and attached the outer diameter to the plywood base of the mold before laying out all the coils and soldering, but it’s imperative that I use 1/2″ plywood for the center parts of the mold since they’ll determine the thickness of the finished stator. The base I’ve been using is 5/8″ and would make for too big of an air gap between the magnet rotors had I used it for the rest of the mold.

Stator Mold with edges slightly tapered for easier removal of finished casting.

Since I didn’t have any 1/2″ plywood when I started winding the coils  I did without it at the time and worked with the supplies I had on hand. As provision would have it,  just as I thought I’d be at a standstill for lack of material, I was able to scavange a perfect piece from the roadside of all places… with enough left over for a lid.

Small Blessings

Tags: Wind Turbine

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