When you make your jig, aim for a 1/4 inch gap on both sides, not just a single cut, because you need the room for your zap ties.
2 and 1/4 might be too big? mine is just less than 2 inch diameter, but as long as you play around with some test coils and figure out how much room you have.
To figure out the turns, I made some 100 turn coils, I could fit 2..3... 4 of them in, 400 turns per window, but then I didn't have room for the overlapping phases, so I figure 300 turns per window, and everything will fit.
Make sure you test these coils in the stator and in the alternator... make sure you have room in the case without hitting the diode board or anything else.
I might replicate the PCB after I get it running, first I will build an aluminum heat sink and mount the diodes on that... wire everything directly.
I am going to test this on my (only) Demonstration Cell... and I was thinking it may work better on a larger tubular array, like Stan's.
I have been working on a design for a 3" delrin resonant cell in the back of my mind. I'll start to think more about that after I get this project done... I also have thoughts on the variable plate spacing cell which I think would be neat and useful to build too...
After the RVIC is wound I suppose you could find the Inductance, and calculate the frequency output at whatever rpm you are using, and if you had a variable plate cell in the range, *maybe* you could resonate, but I dono, it could be tricky.
I am trying to make sure all my coils are wound exactly the same, so if there is a chance of resonance then I will be prepared for it.
What are your designs for an insulated cell? I'd like to see
My diodes are RHRG30120 1200 volt, 30 amp.... These are way over rated, $2.20 each, I bet you would do fine with less amps and less volts, but I wanted to make sure whatever comes out of this alternator I can handle.
