Kevin West has good reference material on the rewind jig.
I'll summarize:
You'll need 14 separate but series-connected coils, the # of winds determine the V.
One example is 62 turns of #26 ga mag wire for each coil, x 14 coils =868 turned getting fluxed at the same instant on a 42 pole stator. This will put out 150 volts I think.
To spool these up, gitcha a length of 1 1/4" sch 40 pvc pipe, at least 12" long. It really helps to have a wood or metal lathe, tho you'll probably wanna crank the turns by hand [by a helper].
Leave the end 2" alone on one end, then slice two cuts lengthwise, 180* opposed.
Now you have something you need to beef up to make it rigid again, but when you remove the "beefers" it'll collapse and you can slide the coils off easily. Also, the slots will enable you to put a couple scrawny plastic wire-ties onto the coils to keep 'em from unravelling.
Now for the layout. Along the pipe, slide a flat piece like a shortened popsicle stick through the pipe, both slots. If it sticks out both sides 1/2" that's enuf. Wrap it in place with electrical tape. This is the "segmenter- beefer." MAke 15 spaces this way, and now you can wrap the right # of turns in each space, leaving a tail at the beginning and a little extra between coils and a tail at the end. Wire is cheap, comparatively.
[edit: he does make reference to winding the coils alternately CW and CCW as you go down the pipe, tho I'm not sure why. Mebbe it has something to do with the way they get wire-tied together]
When its all wound up, carefully slice away the e-tape and pull sticks out after doing the wire-tie thing.
Slide the whole mess offa the slit end and start over for a total of three.
I know this is clear as mud, but I cain't find that file just now
Turtle
