Motor ideal

Guide:- Replication of Windows Bendini/Cole Motor:-
Main tools used:-
-holesaw
-drill press, and drill bits
-hacksaw, sanpaper, file.
Materials:-
-Nylon cutting board from grocery stores
-aluminium channels from hardware store
-brass washers and 3mm diam screws from hardware store.
-8mm diam brass threaded rod for shaft.
-brass sleeves from hobby shop
-2 small ball bearings
-CopperWire, this is at the builders discretion, Some gauges that can be used are .5mm, (24 gauge). .4mm
(26 gauge) and .3mm (28 gauge), and 0.254mm, (30gauge) .
Mike uses:-
.3mm diam 28gauge 46ohms on the larger wire, measured after finished winding.
.254 diam 30 gauge
O.D:- 86mm, standard holesaw size. Instead of doing a write up, I’d thought picture would be
easier:-
Note:- All holes are drilledwith a drill press for accuracy. Use ruler and compass, and measure exactly all
points, even a 1mm difference can throw everything out and dimensions won’t add up, which becomes
frustrating to say the least.
*Important formula to use C = Pie x D, where by pie = 3.142, D = diameter and C is the circumference, R =
radius. When you use a compass, your using the radius value.
Regarding thealuminium channels drill holes precisely dead centre, make it all as accurate as possible, as
you don’t want the disk to wobble around the shaft.
Good idea is to make a template as I have with the 6 holes, on the right of the pic(A). The magnets are held
with rubber hose sandwiched inbetween alum channel and magnet.
You can also add glue to make it fly proof.
Fig(A)
The template is see through,this is also cutting board material, but 1mm thick, so you can just put it over
the drawing/nylon and mark it out.
On the thick Nylon disk, again which is cutting board material, drill the 6 holes on one disc first, making
sure holes line up exactly from the template, then clamp the two discs together and drill the other disc, that
way the holes line up perfectly. I had to make the centre hole8mm for the shaft, so put screws in some of
the 6 outer holes to clamp both together again and drill the centre one. Accuracy is important. The outcome
should be a seamless rotation when finished.
Side view of 2 nylon discs clamped together:-
Both discs completed, holes all lined up, near perfect hex shape:-
Assembled motor, with coil nylon strip holders:-
Side View:-stands 140mm longMeasure distance by winding one or two turns of stout wire ontop of the rotor, making sure it clears it, and
then use that size to make the Jig with handle, makes it easy to wind.
First set I made up:-
first coil:-
.4mm 16ohm, 3rd coil
.3mm 25ohm, main
.25mm 40ohm, trigger
second coil:-
.4mm 13ohm, 3rd coil
.3mm 21ohm, main
.25mm 32ohms, trigger
so total = trigger:- 72ohm, main:- 46ohm, 3rdCoil:- 29ohm
Second set I made up:-
first coil:-
.4mm 22ohm, 3rd coil
.3mm 42ohm, main
.25mm 40ohm, trigger
second coil bifilar:-
.4mm 31ohm, 3rd coil
.3mm 43ohm, main
so total = trigger:- 40ohm, main:- 85ohm, 3rd Coil:- 53ohm
I worked the resistance this way, I measure all 3 x 500gram spools, they were
.4mm = 80ohm I'm looking at 45ohm on my coil so this is about half the spool
.3mm =168ohm Again im looking at over 40ohm this is 1/4 of the spool
.25mm = 400ohm same with this which works out to be about an 8th
Note:- Once you wind your first set, youll know roughly what the values are.
pictures attached of spool jig and coil jig, with this takes about half to an hour to wind a coil....awesome
Notice the white washers made of cutting board material, on the coil runner, thisstops the wire from
collapsing and getting tangled. Also put bearings underneath it, so it runs smoothly.
Coil Jig has spacing of 12mm, which is half the width of magnet, when two sets of coils are finished, Coil
will be same width as magnet.
First set, finished coils shown.
S
mall magnets glued into the disc, 120 degrees apart, used drill press to make indents. This is for timing
charge...