Originally posted by toranarod
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Thanks! It took a while to build, but it could still use some improvements. The rotor is made of White King Starboard Polymer HDPE I got in eBay.
The rotor is 1/2 inch thick. It's very easy to work with wood tools and machines just like wood, but it will melt at high tool rotational speeds. Initially, I just used one layer (1/2 inch thick) for the rotor, but it was somewhat wobbly sideways, so I cut two small circles with a hole saw and placed it at the center of both sides of the rotor for more sideways stability. The rotor shaft hole is tapped for the 1/4 inch diameter threaded brass rod shaft, secured by washers and nuts. I used roller skate bearings with the included plastic tube spacers to center the shaft, since the brass threaded rod shaft is smaller than the hole (5/16 inch) of the bearing.
One improvement would be to remove all the metal screws securing the FWBR's and just superglue it onto the acrylic, because right now it is vibrating really badly and noisily from the magnetic influence of the rotor. I also need to sand down the edge of the rotor because it's not perfectly round as you can see from the rotational wobble in the video.
I have gotten the voltage to around 12 to 13 volts and it is not as noisy at the higher speeds.
-brian
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