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Date: Sat, 02 Aug 2008 21:08:25 -0400
From: Ernest Christley <echristley@nc.rr.com>
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To: Rotary motors in aircraft <flyrotary@lancaironline.net>
Subject: Re: [FlyRotary] Generator development
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Kelly Troyer wrote:
> Ernest,
>     What is the O.D. of the armature ??.........And what is the measurement
> from engine housing and your redrive mount plate ??.........I am using the
> 2nd generation automatic transmission bell housing between my redrive
> and the engine and may have enough space to mount the "Harley' parts.......
>     Have any part numbers ??......I will happily steal your hard work and Idea 
> !!........<:)
>   
The rotor is 1.5" high and 6.5" across.  I have about a 5.5" standoff 
for the adapter plate, but that's an arbitrary number, and is just what 
was needed to fit my one-off PSRU.  I just built the rotor standoff to 
fit. 

To get parts for sizing, I stopped by a small Harley repair shop and 
asked if they had any crashed generators.  The guy pulled one out of the 
trash.  The magnets were half beaten off, and the stator wires were all 
chewed up.  Both were soaked in oil.  I cleaned it up, removed the wires 
and magnets.  Used that for sizing and layout.  You could ask around 
there, or I could send you my "blanks", now that I'm done with them.  I 
don't have part numbers handy, just picked one from the guy's catalogue 
(contact info below).  I chose the one with the higher output, and a 
model that has a shield around the magnets.  That shield has turned out 
to be lifesaver.

To keep all the pieces concentric, I had to shave some material off the 
spline teeth from the inside of the rotor.  The teeth matched up with 
the splines in my stub shaft, but I needed it to slide up further than 
that.  It machined easily enough on the lathe, and I kept it to a tight 
slip fit over the stub shaft.  (This was where the shield came in 
handy.  The chips wiped right off with a terrycloth rag.)  That centered 
the rotor.  I used 7/16" shear bolts to attach the rotor to the 
standoff.  7/16" because that's the size of the pre-drilled hole in the 
rotor, and shear bolts because I needed for the head to lay low and not 
interfere with the stator.

The standoff's center hole was also a tight fit on the stub shaft.  Once 
the clutch adapter plate was slid on, with the splines forcing the 
alignment, everything was centered and then match drilled.  One side of 
the rotor was a little high by about 1/16", so I pressed it down using 
my vice.  A standoff cut from a round block of aluminum would probably 
be a better design.

I need to add a shield plate between the stator and PSRU.  I've got some 
thin gauge stainless that I'm going to use for that.  Just cut a circle 
and bolt between the stator and PSRU to keep grit from flying into the 
rotor.


Jimmy Winters
Custom Cycle and Parts
10119 Chapel Hill Rd.
Morrisville, NC 27560
919-469-0811


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