Discussion on Electronic Stators

[soullad]

Excellent thread fellas. Looking forward to more posts / pics.
Any tips for increasing heat dispersion or is it not necessary?

[coaster]

^... Colin, thanks for posting the photos. I've had zero chance to upload them to a host site, etc. so do appreciate you posting them. However, would it be rude of me to point out that photo 2 seems to have been posted twice? That said, it took me 20 minutes of playing 'spot the difference' before I realised that it was the same

WCW... yeah, looks a bit half-hearted!

Adam

Oops, now corrected Adam

[coaster]

Excellent thread fellas. Looking forward to more posts / pics.
Any tips for increasing heat dispersion or is it not necessary?

Cheers Ian, heat was an issue I asked about earlier in the thread but I havn't come across any mention of it despite extensive googling on stator repairs. We'll see.the wire I'm using can stand up to 200 degrees Celcius so should be ok.

I unraveled the standard coils on a standard SIL stator this afternoon and found 70 and 72 turns on the large coils and 59 and 60 on the smaller ones. The wire that I ordered arrived and at 1.25 mm Sq it is slightly larger that the WCW and SIL wire which measured 1.10 mm sq. I had a go at putting 80 turns on a large bobbin but it was way too big to fit on the stator. I reduced it to 65 turns and managed to get it on but it might still be too big and interfere with the adjacent coil. My understanding tough is that I can use fewer turns with the thicker wire, the voltage will be lower throughout the rev range but it will give higher currrent.......sounds a bit like a torquey tune sort of thing, lower bhp but more torque? I'll resume tomorrow but I'm worried that I won't have enough wire

As an aside, I attempted to unwind an LT coil but gave up at around 840 turns as the wire kept breaking due to the amount of lacquer used. My guess is around 1000 or so, anyone any idea?

[sideout]

Ahah, another HM Dockyard apprentice eh? I was a Chatham Dockyard apprentice, transferred to AUWE Portland when Maggie closed Chatham Obviously an eye for detail

AUWE Apprentices Rule OK :bouncing:

[soulsurfer]

OK!

[Adam_Winstone]

Colin,

Cool, thanks for the edit.

You'll notice that I wrapped a thin layer of masking tape around the coils before fitting them, which may or may not be mentioned in Tony Mc's JetSet feature (can't remember) but it is something I've noted on some factory assembled stators. I have also traced 2 faulty SIL stators to cure lighting issues, where the failure has turned out to be the heavily wound bobbins allowing the copper wire to earth out on the underside against the stator base. In both cases I've wondered if this failure through the wire's coating was caused when it was forced home onto the laminate core (scratching the underside) or through tight fit and general vibration. Either way, I thought that the tape would serve to better isolate the copper wire from the stator's base plate.

To date this stator has served me well in respect to ignition and lights. It's been on my cutdown for a couple of years now and has yet to fail (fingers crossed!).

Adam

[rosscla]

I recently dismantled and rewired an SIL electronic stator as per the DC conversion (going to do my old AF one next), all the coils has a piece of cloth 'tape' behind them which seemed to be insulating the coil from the back plate.

I found remounting the coils a bit of a game. Is there a good way of sorting the previously bent laminate that's folded over to make the coils easier to remount?

[Adam_Winstone]

^... not that I know of. Just try to keep the folding/bending of the plates as uniform/regular as you can (using a large'ish flat tool for prising them down, then a suitable large flat tool for knocking them back up). If you lever them with skinny tools then you tend to put extra creases in the plates, which makes it harder to remove/re-fit coils.

Adam

[coaster]

....Is there a good way of sorting the previously bent laminate that's folded over to make the coils easier to remount?

As Adam said but if they are already wrinckled as were mine by using too small a tool I found a pair of Gas Pliers were very good at flatening the damage but the laminates tend to seperate and it's almost impossible to squeeze the laminates together whilst pushing the bobbin on. I ended up filing a shamfer on the inside of the bobbin to held ease it over the splayed laminations.

[coaster]

.......I reduced it to 65 turns and managed to get it on but it might still be too big and interfere with the adjacent coil.

ARSE :flaming: Still too big, I'm going to try 55 on the big bobbins and 40 on the small ones. That's still more turns than the WCW stator which had 42, 26, 40 and 30 wound directly onto the laminates and I'm fairly sure was charging ok and that was with slightly thinner wire The good news is, I think I have enough wire