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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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http://www.ronpaultimeline.com
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