How to Make a Strong Genorator

this project came to me after i had noticed that there is not many differences between a ac motor coil and a dc motor coil. well the only difference was the size. so i got started!

the tool list that i used is quite extensive and some exeptions could be made the tools i used will be listed below
drill press
lathe
philips screw driver
welder
a black and white marking pen
hobby knife
table saw
square
hack saw
silicone

supplies
plastic block (size will vary to the size of your motor coil)
AC motor coil
magnets
brushes and springs (be sure that they are from the same motor coil)
key stalk
sheet metal
small pieces of tin
washers
bolts
screws

first you wnat to organize what you want to do first the frame or the motor. i started with my frame. i would show you step by step the drilling and welding but i had to make it first to make sure it works

the first thing that i did was took the key stalk and cut they in two lengths and put the two smaller pieces parallel and the longer pieces on top so they are on the edges of the smaller pieces. double check to make sure that it is square then weld it together. then take the sheet metal and weld it to the bottom of the long key stalk. then with a piece of sheet metal that is the same width as your plastic block. center your plastic block on the piece of metal you cut and mark the metal with the white marker were the plastic ends on each side then drill a small hole in each corner inside were you marked for your screws. keep the holes as close to the corner as possible  to avoid having a screw go in to were you will have to drill on the block. then square up the plate on top of the long key stalk closer to the middle and weld it down

now to work with your block first cut it to the size you will need it. take the black marker and draw a X from corner to corner on the large face to easily find the center of the block. now that you have center found, drill a piolet hole then drill a hole the same size as your motor coi.l after you have done that check your clearacne between the coil and the hole you just drilled i gave my self 2mm clearacne you might have to use sand paper to get the extra clearance.
now flip the block on its side and X 2 sides then drill a piolet hole and then drill a bigger hole that is a little smaller then the magnets and drill all the way through both sides of the block then rotate it and do the same thing to the other side. once all 5 holes and drilled put it on the lathe and shave away the plastic till the magnets fall in. make sure to leave a thin lip so the magnets don't fall through to the coil.
now take the hobby knife and clean up all rough edges  

ok now that you have your frame built and your block drilled. now you need to finsh drilling on the the frame to put it all together
the first thing that you want to is take the same size of bit that you drilled the screw holes. then drill in the screw holes and through the bottom plate. flip the frame over and take a bigger bit and drill only through the bottom plate so the screw heads will go through

this part is important part in making the motor work proporly
you must arrange the magnets two of the 4 magnets side by side as - and the and the other two side as positive. i learnt that the hard way the first time i did it i arranged the magnets +-+- instead of --++ .once you have that done that fill the hole up with silicone so that they will not fall out

at this point you are almost finished.
after the silicone is dried, place it on the metal piece that you cut to the width of the block and screw it down tight but don't strip the block now set in the motor coil temporarily to mark directly below the end of the shaft on both sides now remove the coil and drill a hole were you marked with a bigger bit than your bolt so that you have a little movement to adjust the motor coil to get center with no rubbing on the plastic. now put your motor coil in the block, slide the tie rod ends on the shafts of the coil. put one washer on the bolt and put it through the plate then put one or two more washers on then the nut and then the tie rod end. do this to both sides. the using slight movements center the coil in the block so it spins freely in the block, make it hand tight until you have them both were they need to be. now take a couple wrenches and lock the bolt (what i mean by this is turn the nut down towards the plate with one wrench and turn the bolt up with the other.


well thats it... almost in order for the motor to work you need power and something to transfer the power to the coil. the brushes!! now you need mount the brushes for this part i didn't do any thing special i drilled a hole in a scrap plastic just large enough to fit the spring and brush then cut a slit in the plastic that goes down to the hole then slide in the tin pieces so the spring presses against the tin and the brush when its on the coil then i screwed it to the block