DIY Stators

So having diagnosed CJkit’s electrical problem as a severely burnt out stator, I took it into my head to try and recondition it. I suffered no end of electrical problems when I owned a Triumph. Several varieties of regulator and stator, they all burned out between 2 and 6 thousand miles. The idea here was to rebuild the stator with quality materials, slightly lower gauge wire and more loops per pole. The theory is more windings give more amps available at low rpm. I had always thought that the electrical varnish they use wasn’t really up to the job, so planned to upgrade that too.
It looked like this;
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

what was the A/C voltage like?

30-40VAC at idle from each phase. Minimal voltage difference between phases at a steady idle. Resistance of 0.5 Ohm through every phase, which is at the low end, implying my wire was of better quality than Triumph’s :smiley:

what about at 5krpm where its tested?

65 VAC @ 5000k

ps: Cj, if your bike explodes tomorrow morning, you mind keeping it quiet for a bit? :stuck_out_tongue:

tiny bit low but a bloody good bit of work there young man. :cool: interested in longevity report :slight_smile:

What you think Matt, does it have chance of surviving? I’m still fairly shocked it worked at all…:smiley:

it cant be any worse than an electrex world one tbf, it it makes it 2 months you will have beaten the worst i have seen of theirs :smiley:

Fair play for trying that one .That PDF contains most probably is what you want to coat it in .

Really interesting post, thanks for sharing this with us Scorch!

I’ve always wanted to do this with my old Fazer to try an help power the extra headlamps and heated grips…

More ‘how to’ posts like this please! :slight_smile:

Shame you weren’t around when I was trying to get my Husky running, could have done with your electrical diagnostic skills! It’s now on eBay as a non-runner cos of an intermittent spark…

It’s a bit early for me to claim success, but if CJ racks up a few miles then I’ll happily put together a detailed ‘how to’ when I do the next one. To be honest it’s not difficult, just a bit tedious. :crazy:
Rob, that’s exactly what I’m looking for. I reckon masking up the mounting points, then really coating the windings up with that stuff would armour it nicely.

Can I ask, why did you cover it in JB weld? Is it in order to insulate everything?

Why do you have to insulate it if the copper windings already have a coating on the wire?

Well done that man - proper job

What was the time scale on that

Did Paul Heaton and David Rotheray know about this stator winding on a table leg or maybe they just couldn’t get it to scan

Bloody nice job Tim :-). I’ve had to hand wind a couple of transformer couls before but nothing on that level of complexity. It’s a tedious and time consuming job that needs a lot of concentration and precision. Well done!

good job McGyver! :smiley:

The winding took me about 11 hours, but around half of that time was spent cursing at it. Once I got the knack it wasn’t too bad, I could think I could half that time on the next one.
I used JB weld to seal and protect the windings. In theory, there should be no gaps between the wires, which is hard to achieve. The wire is protected, but I don’t think it stands up well to direct contact with 200 degree oil over a long period of time. I like the stuff NumNum suggests, I think next time I’ll make a mould and pour the stuff over the windings.
I haven’t heard from CJ for a couple of days though…:ermm:

Haha! Wasn’t able to get out on it this weekend but I’m just about to head into town. I’ll let you know if it gets me home again! :wink:

Posted 13 hours ago

Does CJ live that far out of town

11 hours! Fook me. I had to have mine sent for a rewind & was charged £130 for the pleasure. Thought that was a lot but maybe not…

cracking effort! fancy making up some light weight race stators?!!