Re wind Your Own Motor
Click on images to enlarge

This is my stock motor before removing the factory winds. I have bent the tabs out in preparation for the unwinding process.

I used a tweaker (small screwdriver) to get under the tabs and bend them up.

After that I just unwound the wire ...

 

Here you can see the armature sans wire. I simply unwound it. This armature is from an older, non rebuildable stock motor.

Stock motors have 27 turns of wire around each pole. There is only one strand that does the wrapping, so it is called a 27 turn single.

 

Here is the blank arm from a different perspective. Not sure why I threw this image in, but it is kind of interesting.

Well, I had two choices, assuming I wanted to reuse the existing wire:

1) 13 turn double
2) 9 turn triple

I opted for the 9 turn, because what the heck, if I am going to do something silly, I may as well do it silly and fast!

I started winding the motor a 13 turn double ...

 

But, I figured I may as well go for the 9 turn when I saw how much excess wire I had. This wind you see here was just a test.

To prepare the wire, I wrapped it twice around the smooth shaft of a Phillips screwdriver and pulled the entire length this way. It removed the kinks and sharp bends (from being on the armature previously).

I actually had to do that twice because of this test run

Here is the 9 turn triple variant.
The wire has a coating on it to protect the stands from electrically connecting to each other. The coating is a very tough enamel. I used an Exacto knife to scrape the part off that will be connecting to the tabs. I used a high content silver and soldered the wires onto the tabs. It was not easy, and the plastic underneath the copper commutator actually warped a bit. After quite a few passes on the lathe everything came back into shape. I also did some poor man's balancing with a drill.

This did not work out as planned :)
It appears that I need much higher temp solder, a tighter wrap on the winds, and a better way to balance the arm.

Oh well, it was just for fun anyway. I'll try again later, when I have the proper stuff ...

 

  © 2007 TE Shreve
Last updated 02/11/07