WELL WE FINALLY CAST THE STATOR. THE WIFE AND I HAD A BALL. I HOPE YOU ALL HAVE AS MUCH FUN AS WE DID. THE CASTING WENT LIKE A DREAM, EXCEPT FOR ALL THE BUGS THAT SHOWED UP FOR THE 500 WATT LIGHT. IN THIS VIDEO WE CAST THE STATOR, AND SHOW TIPS FOR MAKING IT COME OUT RIGHT. GREASING THE MOLD, MIXING THE POLYESTER RESIN, WHY WE USE BABY POWDER IN THE MIX, PAINTING THE MOLD WITH RESIN, THE FIBERGLASS SHEET, RESIN, THEN COILS, MORE RESIN, THE NEXT FIBERGLASS SHEET, AND THE REST OF THE RESIN. THEN WE SEAL UP THE MOLD AND SCREW IN ALL THE SCREWS. MUDDy
Video Rating: 4 / 5
25 comments
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muddymuddymuddmann says:
February 9, 2012 at 12:57 am (UTC 8)
@1alan1977 YA THE PLAN IS TO SHOW START TO FINISH CONNECTIONS , TOWER AND ALL. ALTHOUGH AFTER A THOUGHT OR 2, I REALIZED THAT 3 METERS IS VERY CLOSE TO THE DESIGN I AM? MAKING. NOT MUCH SIZE SCALING THERE.
HOWDY FROM TEXAS.
AND THANKS!
MUDDy
1alan1977 says:
February 9, 2012 at 1:20 am (UTC 8)
cheers ,Muddy, appreciate your advice, will post on tube soon as I time to get on with it, really got the bug now and hopefully will start building in next couple of weeks. keep up the work with the vids, finding them very informative, have you set up battery banks and wiring if so are you going to post it ?? again thanks Alan ,norfolk England :)
muddymuddymuddmann says:
February 9, 2012 at 1:50 am (UTC 8)
@1alan1977 THE COWLING WOULD BE OK AS LONG AS YOU LEAVE ROOM FOR AIRFLOW. REDUCING THE SIZE OF THE ROTORS WOULD MAKE THE SPEED OF THE MAGNETS PASS THE COILS MUCH SLOWER, THUS LESS VOLTAGE AND POWER. IF YOU GO FROM 11 INCH TO 10 INCH MAGNET ROTORS, YOU COULD EXPECT A DROP OF 10%. HOLES IN THE STATER WOULD DROP STRENGTH A BIT, BUT I THINK THE STATER IS PLENTY STRONG ENOUGH TO DO THAT WITHOUT ANY CONSEQUENCES.
KEEP AT IT. I’M? LOOKING FORWARD TO SEEING IT ON THE TUBE.
MUDDy
1alan1977 says:
February 9, 2012 at 2:38 am (UTC 8)
Thanks for the reply, I was thinking of using 3 mtr radius prop and thought maybe could reduce size of rotors and stator a little without compromising output to much mainly for aesthetic reasons,also do you think it would be a mistake to have holes in fibreglass in centre of coils to cool them or would this compromise the structure to much ? 1 more thing sorry? to be a pain just wondered if all the axial s ive seen have been left exposed for cooling reasons as i would like to cast a cowling ?
muddymuddymuddmann says:
February 9, 2012 at 2:57 am (UTC 8)
@1alan1977 ESPECIALLY GOOD QUESTION ALAN.
SCALE IT ALL DOWN AS MUCH AS YOU WANT. THEY SHOULD WORK WELL. ALTHOUGH THE POWER AVAILABLE IN THE WIND DUE TO DIAMETER OF THE PROP IS THE MAIN THING TO SIZE YOUR NEEDS.
WHEN THE PROP IS SHORTENED BY 50%, THE POWER FACTOR IS ONLY 1/4th.
WHEN IT IS DOUBLED IN DIAMETER, THE POWER FACTOR IS 4 TIME HIGHER.
ALSO WHEN THE WIND IS DOUBLED, THE? POWER FACTOR IS RAISED 8 TIMES.
KEEP THE MAGNET ROTORS 1/10TH THE PROP SIZE.
MUDDy
1alan1977 says:
February 9, 2012 at 3:41 am (UTC 8)
Hi been watching youre videos and finding them really informative and prob the best explained vids on this, “great job muddy”, just wondering if you could tell me if these could be scaled down on exact principle? and if so how much would this affect output? and would i need any any alterations in any areas other than scale,,,would appreciate your help ,,,Alan (England) :)
muddymuddymuddmann says:
February 9, 2012 at 4:19 am (UTC 8)
@saracenjohn HA HA!, I HAD A FRIEND THAT TOLD ME TO USE McDONALDS FRENCH FRIES. IT’S AMAZING. IT? DE-GLUES ALMOST ANYTHING FAST. I FIGURE IT GETS INTO THE SKIN AND RELEASES WHATEVER STICKS TO IT. AND IT DISSOLVES TAR TOO.
saracenjohn says:
February 9, 2012 at 4:28 am (UTC 8)
just did this step on my turbine, gloves are an absolute must!!! i spent 2 hours trying to get the stuff off my fingers and there still sticking to my keyboard as? i type haha, best thing to remove it, i found was butter and washing up liquid, great vid muddy, i couldnt have made mine without it, thanks john.
muddymuddymuddmann says:
February 9, 2012 at 4:36 am (UTC 8)
@JOHNNYH8STHENWO OH… I FORGOT…
MRMUDDYSWIFE IS GOOD WITH THE CAMERA, AND WITHOUT THE CAMERA. LOL. SHE WOULD? BEAT ME IF I DIDNT GIVE HER CREDIT. SHE HAS TO BE GOOD TO PUT UP WITH ME. AND SHE CAN COOK PRETTY DARN GOOD TOO. BEST OF ALL… SHE HAS MAGICAL FINGERNAILS FOR SCRATCHING MY BACK.
WWEEE!
MUDDy
muddymuddymuddmann says:
February 9, 2012 at 4:52 am (UTC 8)
@JOHNNYH8STHENWO HELLO O GREAT JOHNNY!!!,
MAGNETS NOW ARE ABOUT 13.00 BUCKS EACH X 24. 11 POUNDS OF 14 GAGE MAGNET WIRE…95.00 BUCKS. YOU WILL NEED 7 POUNDS FOR? THIS. ALLTHREAD AND NUTS, ABOUT 40 BUCKS. THE HUB SPINDLE AND BEARINGS AT NORTHERN… ABOUT 45 BUCKS. USED BRAKE ROTORS…FREE TO 20 BUCKS, DEPENDING ON HOW AND WHERE YOU GET THEM. FIBERGLASS RESIN = 1 GALLON..$25.00.
WELDING RODS AND A FEW 3/16ths THICK X 2 INCH FLAT IRON. 6 BUCKS. THAT ABOUT COVERS IT BESIDES THE WOOD FOR BLADES.
JOHNNYH8STHENWO says:
February 9, 2012 at 5:18 am (UTC 8)
MRs MUDDy is a pretty good camerawoman.
I was curious, how much do you think it would cost to build one if you knew someone who had the tools? I know a couple people, but I’m not so sure they would let me use? their tools that extensively unless they were getting something out of the deal.
muddymuddymuddmann says:
February 9, 2012 at 5:45 am (UTC 8)
@TheDarkeJ YA WE HAD A BALL DOING THIS ONE. IT’S HARD GETTING INTO THE PROJECTS ON CAMERA. BUT SHE ENJOYS IT WHEN WE DO. I LIKE THE PART WHEN SHE DROPPED THE CAMERA? BEST. SHE THOUGHT I WAS GOING TO EDIT THAT OUT…NOT…LOL. WWWEEE!
LOTS OF FUN.
MUDDy
TheDarkeJ says:
February 9, 2012 at 5:55 am (UTC 8)
hey bru, my wife and I watched this one together, lol, we had a ball? listening to ya’ll’s comments! Good work on that jig mold!
muddymuddymuddmann says:
February 9, 2012 at 6:31 am (UTC 8)
@tectalabyss GOOD QUESTION, LOL. LETS SEE… PROBABLY MOVE THE SHOP INSIDE, DRINK FROM THE MILK CARTON, STARVE A LITTLE, WASH ALL CLOTHES UNSEPARATED, TURN THE MUSIC UP LOUD, AND RUN WITH SCISSORS. OH AND SYMPATHIZE WITH THE DOGGY.
THANKS. I’M DOING DRYWALL NEXT DOOR FOR? MY NEIGHBOR FOR A FEW DAYS. HIS HOUSE IS LOOKING GOOD SO FAR. BUT HE TIRES OUT PRETTY QUICK. SO I’LL STILL BE DOING THE VIDEOS. ALMOST FINISHED WITH THE NEXT ONE.
MUDDy
tectalabyss says:
February 9, 2012 at 6:47 am (UTC 8)
Hi Looking forward to the next video.Yes and what would we do without our better half’s .Liked and added to my? Favorites.Thanks for sharing.Tec
muddymuddymuddmann says:
February 9, 2012 at 7:04 am (UTC 8)
@MRMUDDYSWIFE AS SOON AS YOU GOT A PROJECT OR NEED FOR IT. LOL. JUST GET IT. WWWEE!
SHE’S SO SWEET,
MINE ALL MINE,
GUESS I’LL KEEP HER,
ALL THE TIME.
EYES LIKE CRYSTAL,
TEETH LIKE PEARL,
LIPS LIKE PEDALS, (BICYCLE PEDALS)
I THINK I’LL GIVE HER ANOTHER WHIRL.
WWWEEE!
JUST FOR YOU, FROM YOUR LOVING HUSBAND.
MUDDy (ALIAS…,YOUR FAVORITE GOOBER)?
MRMUDDYSWIFE says:
February 9, 2012 at 7:40 am (UTC 8)
I had a lot of fun helping you on this project. Now when are you going to give up the camera and let me make my own?
MRMUDDYSWIFE?
muddymuddymuddmann says:
February 9, 2012 at 8:09 am (UTC 8)
@yellowmetalcyborg FOR A SUCCESSFUL DESIGN OF WHAT YOU WANT,… WE HAVE TO START WITH ,(WHAT VOLTAGE YOU NEED),? AND (WHAT RPM YOU THINK YOU WILL HAVE FROM THE FALL OF WATER.) AND VOLUME OF WATER.
GOOD TO HEAR FROM YOU. HOPE YOU HAD A NICE 4th OF JULY.
MUDDy
yellowmetalcyborg says:
February 9, 2012 at 8:19 am (UTC 8)
@muddymuddymuddmann Ah, I feel so stupid, I thought you were using epoxy, my bad. I’ve never worked with polyester resin, I might give it a try soon. I have a stream near? my house that is ideal for microhydroelectricity and I need some kind of alternator. It’s a very small stream, so I can’t afford to use an inefficient alternator. I might be giving this axial alternator a shot.
muddymuddymuddmann says:
February 9, 2012 at 9:00 am (UTC 8)
@yellowmetalcyborg POLYESTER RESIN ISN’T AS? BAD AS EPOXY TO WORK WITH. I HAVE PRETTY GOOD WIND HERE TO KEEP THE SMELL AND VAPORS AWAY PRETTY GOOD. ALL WEEK WE HAD 15-20 MPH WINDS. THAT NIGHT WE HAD 5-10 BUT KINDA STEADY. IT WAS NICE WORKING ON IT THEN.
I LEARNED OF THE TALC POWER FROM OTHERPOWER’S DAN BARTMAN. I FIGURE A PERSON LIVING 15 MILES FROM THE NEAREST GRID AUGHT TO KNOW HIS STUFF. I DUG INTO EVERY WORD I COULD FIND ON HIS SITE FOR A YEAR. DAN HAS BEEN PRETTY GENEROUS TO THE WORLD.
yellowmetalcyborg says:
February 9, 2012 at 9:06 am (UTC 8)
Interesting… I never thought about mixing baby powder with epoxy, nice idea! I’m sort of allergic to epoxy though,? even if I use it outside. It’s some pretty nasty stuff.
muddymuddymuddmann says:
February 9, 2012 at 9:59 am (UTC 8)
@MrHorsetail 77 TURNS OF 14 AWG GAGE DOUBLE INSULATED HIGH TEMP ENAMEL? WIRE.
ABOUT 7 Lbs.ALL TOGETHER. 9 COILS.
HOW MANY FEET, I DO NOT KNOW.
MAN IT’S A HOT ONE HERE TODAY.? HAPPY 4th OF JULY.
MUDDy
MrHorsetail says:
February 9, 2012 at 10:18 am (UTC 8)
Hey? mud, what gauge wire is that and how many feet do you think you used?
muddymuddymuddmann says:
February 9, 2012 at 11:01 am (UTC 8)
@peppino66castro AH THE FOURTH OF JULY. CANADA CELEBRATES THE EQUIVALENT OF THE 4th ON THE FIRST OF JULY. IT IS THE BIRTH OF CANADA. BUT HERE WE WILL CLIMB ON TOP OF THE ROOF AND WATCH THE FIREWORKS UP THERE. WE CAN SEE 5 DIFFERENT TOWNS CELEBRATE AT THE? SAME TIME. THANKS FOR THE WISHES. ENJOY THE CELEBRATION AND HAVE A COOKOUT OR SOMETHING. GOD BLESS YOU.
MUDDy
muddymuddymuddmann says:
February 9, 2012 at 11:35 am (UTC 8)
@wtam69 OK YOU GOT ME THERE, I CANT PULL OFF ANYTHING AROUND MY MOST? OBSERBVANT VIEWERS. WAIT UNTIL WE MAKE OUR VERSION OF RUM BUNT CAKE. WE HAVENT FINISHED ONE YET. THE RUM KEEPS EVAPORATING TOO FAST OR SOMETHING.
MUDDy