EpoxyLite Insul Spray

[vbad_ben]

Does anyone know where I can find some EpoxyLite Insul Spray 7001, i've looked all over the internet but no luck

[sledge]

I am familiar with Epoxylite products, but not the one you mention. They are made by Sterling Technologies in Manchester and used extensively in the Electromechanical repair and manufacturing industries. They are not generally available direct to the public in small quantities. They might supply you with a small amount as a sample if you ask them nicely.

http://www.elantas.com/uk/
http://www.applegate.co.uk/chemical/company/co_7456.htm

Alternatively these companies may be able to supply a similar product in small quantities.
http://www.aev.co.uk/
http://www.applegate.co.uk/elec/company/co_1203482.htm

Am I right in thinking you are going to attempt to rewind your stator?

[vbad_ben]

Yes that’s right not sure if it's going to go horribly wrong but might as well give it a try. Apparently 3M 2116 and 3M 1838 also work but I can't find these either. Do you have any suggestions of spray on insulators that are easily available?

[The Buddha]

Owww ... hand wound stator ... I did that. I'd use JB weld though instead of any fancy insulator crap. You want it to dissipate heat.
BTW the factory wound stator was soooooooo far superior to mine, its not even close.
I believe you almost have to cut the wire to length and insert wind it after the first set of windings. It has to be perfectly lined especiaklly the bottom 2 layers in each pole. The poles have 3 layers of windings. Get the first 2 screwed up and the third will be a mess.
Cool.
Srinath.

[sledge]

Firstly a self-wound stator using standard magnet wire will not have the lifespan of an original. The original will have been wound using self-bonding wire, this is wire that has a thin coating of "glue" on top of the enamel, the idea being when heated it fuses together and bonds each turn of the coil together, it prevents the turns from becoming loose. Its only available from specialist wire suppliers and expensive in small amounts. Spray on varnishes will not penetrate inside the coil and wont hold the inner turns together, over time the turns vibrate, expand and contract and the insulation breaks down between turns, this is what I suspect is wrong with your original stator. Bonding wire or epoxy impregnation is the most relaible method.

Its vital you use wire of the same diameter as the original, you need to burn the enameling off and measure it with a micrometer to obtain the correct size. Also vital is the amount of turns, must be same as original and equal turns must be placed on each pole-piece. The coils must be tightly wound on the pole pieces in the same direction as original and the copper wire must be insulated from the pole-piece and kept away from any metal that may otherwise cause it to breakdown to earth. There is also the risk that the plastic former between the coil and pole-pieces might become damaged when you remove the old winding.

I havent actually rewound a bike stator myself but I do know whats involved, the links will shows pics of the kind of equipment that I get involved with almost daily....just a little bit bigger  

Best thing you can do is contact one of the companies in the earlier links, Wire Electric supplies LTD. Tell them what you are doing and ask them to advise you on the most suitable materials. I know whats involved but unfortunately I dont know what the best products actually are for a tiny job like this.

I really do think, given you buy a new one for about £60 with a 1 yr guarantee its not worth the hassle and cost of even attempting to rewind it but I respect the fact its your choice.

http://i224.photobucket.com/albums/dd92/iainmcdermott/red-motor-stm-rewinds.jpg

http://i224.photobucket.com/albums/dd92/iainmcdermott/motorRewind.jpg

[The Buddha]

I used double enamelled copper wire. I however put so many twists and kinks in it by the time I got it done, it was a misery. The idea is to essentially cut it to length and use the needle and thread method of winding it wihtout kinking it.
You can dip each layer in epoxy if you like, but machine wound can have more scratches and nicks in the enamel than hand wound, if you knew what you were doing. I didn't but I knew enough to buy a used one and drop it in once I wound mine.
Cool.
Srinath.

[vbad_ben]

You say 60pounds? I have looked for a stator at this price and apprently you can only buy one for a gs500k3model from Suzuki for 180pounds. If you can find me a stator for 60pounds new, bugger rewinding the thing!! lol 

[sledge]

I did post this link in a previous post you made relating to the problems you were having, you must have missed it.

http://www.electrexworld.co.uk/erol.html#1X0

According to the table, the GS500E uses a G1 generator......£45 plus VAT and del.

[ohgood]

Way back when, I used to build production tooling and simple stator hand winding machines for Delco/GM. We called them little pieces of hell, because the operators would get tired and take a hammer to them. Disassembly of just the hand operated winders was time consuming, and everything depended on everything else to be disassembled. WOOT !

Now, if I had a real conviction and a weekend I might be able to wind my own. Given my experiences with what is a good stator, and what is a worthless stator, such a small difference is like farting at the wrong time. Not to mention it could start a nice little fire. Nick a wire here or there and things get interesting.

Good luck if you decide to do it, but even MY cheap bones wouldn't attempt it. I'd find a wrecker and strip it, beg, borrow, or heh, steal one.

2 cents 

[GeeP]

heh  Sounds like fun. 

I know a guy a few towns over that rewinds motors and generators by hand.  Last time I was in there he had a 1,000 HP 440V armature between a couple of overbuilt steel sawhorses.  He'd just cooled it down from the stripping oven.  I asked him when it would be done and he said:  "Oh, we'll have it ready for varnish before midnight."  Should have seen them work though.  Six guys and six spools of magnet wire.  I'll bet they could wind a GS500 stator in their sleep with one hand tied behind their back.    

I don't have the patience for that stuff.   

[vbad_ben]

Well I spoke to the guys at electrex and they said it doesn’t fit the k3 model but I just rang back and apparently it does. So all that hassle for nothing.

My stator is on its way thank-you everybody for all your help. 

[The Buddha]

heh  Sounds like fun. 

I know a guy a few towns over that rewinds motors and generators by hand.  Last time I was in there he had a 1,000 HP 440V armature between a couple of overbuilt steel sawhorses.  He'd just cooled it down from the stripping oven.  I asked him when it would be done and he said:  "Oh, we'll have it ready for varnish before midnight."  Should have seen them work though.  Six guys and six spools of magnet wire.  I'll bet they could wind a GS500 stator in their sleep with one hand tied behind their back.    

I don't have the patience for that stuff.   

Naaaaa ... you gotta think small, very very  small ... like trying to jerk off an ant ... not an, ant.
Big crap is easy, every one tells me they cant do bikes cos sheite is too delicate and frail. Same here. technique is important, but this is just having the fingers to get it done.
Cool.
Srinath.

[GeeP]

Well I spoke to the guys at electrex and they said it doesn't fit the k3 model but I just rang back and apparently it does. So all that hassle for nothing.

My stator is on its way thank-you everybody for all your help. 

Good to hear.