Hey, those discs appear familiar. Did you burn them yourself? or are they a find? Do they have a slight beveled edge?
What's the diameter?
Anyway, i still have about 30 of similar size , i think. Mine are 13" in diameter, 3/4" thick, slightly beveled, i recall around 30 lbs. Plucked them out of a dumpster about 7 yrs. ago.
If anyone local to me can use one for this purpose, i'll give it free.
I was going to use some for footpads on a tiny house, and tractor wheel weights.
Keep up the good work/diagrams/pics!

They were a dumpster grab, a very slight bevel around the edge so that denotes plasma cut rather than flame. I wasnt going to go into this but since you have disks and someone may try this...you will note that there are not others of this design on the net. There is one other that the otherpower Dans built for there Listeroid at 650rpms, they dont mention it on their web site but I gather through corispondance that they burnt the first one up.
This type of construction is perfect for windmills opererating at low rpms, once you start driving these with a engine the 3phase frequence climbs fast and if your not carefull selecting rectifier diodes you may find you have built a electric brake rather than a alternator due to the fact that the diodes need to be able to switch at the frequence applied. in my case this alternator will be 12 pole with a target rpm of 1800 so that means the frequence will be 360hz selecting the wrong diodes means you could have diodes that would avalanch (short) at that freq..just something to be aware of if you build one, not a problem you understand just something you need to pay attention to, and if you dont you may let the magic smoke out.
By the way Your 13 inch disks are a perfect size for a dual rotor windmill project......
This project now goes into slow....mode.... as if I am going to this effort to get better fuel economy I am also going to put my attention to a regulator cct ( will work fine without one )that will help milk more kwhrs per liter burnt. still decieding on series pass or shunt, will take me a while to decied what way to go.

I am going with 12 magnets, 30 degrees apart, best to paint the disk, then its easy to scribe your marks. I just layed my paper template over top and using a center punch mark where the mag's will go, at this rpm its best to use mag cups as I wouldnt trust glue/fiberglass alone to hold.
If the disks have been plasma cut, then its best to do your measuring on the top of the plate as it will be the roundest/truest, not that the bottom will be out by much..just a case of best practices.

I am thinking the coils will be 16 gauge wound 2 in hand (maybe 3) 14 turns...just a wag , as I stand no chance of being able to do the math, but I am a good estimator.

I could use the wire out of that stator I pulled off, it looks to be 18 gauge so I could wrap my coils 4 in hand, and that should work, but I have a spool of 16 gauge I would like to use up, so thats why I am going 16 gauge.

I should add while I am building this as a low voltage 3 phase (low ripple,PtoP)charger for battery banks. you can build one for single phase 120 volts AC at 60 hz as well. In fact I have some from the 60's and 70's, 1600 watts and I think 3000 watts...2pole units and guess watt, that was from before neo mag's were invented..thats right they could be built from ordinary ferrite mag's,and they worked great, outstanding load regulation (or so I have found) and they could punch out huge surges of current for compressors, or table saws on start up, they kicked ass ....lets play a game...who can guess why they wernt that popular? (3 reasons)

Funny you should mention low ripple chargers. Picked up an old Eico 6/12 low ripple batt charger/eliminator a few weeks back. I'm hoping to use it for a splooge tank in the near future.

I have decieded to make a wooden form for wraping my coils to, the other way of wraping each coil, then you have to get them spread out, fastened together....it all takes time and this way should speed things up a bit, and be easier...i like easier

now I will just have to cut away the extra wood....dont really know if this will work, im just making this up as I go along.

This is going to go slow, I should have a proper router but I only have a moto tool so this is going to take a while, but I routered out my first coil location

that magnet just sitting there is the diameter I will use but not the thickness I will be using ones 3 or 4 times the thick ness

The cutting ball is so small it takes many passes

First lesson learned was put away the moto tool and go borrow my niebours router...done in a half hour
This pic should show that I am using a bit that undercuts .

Never used a router before, what a handy tool....I think santa will be bringing me one, and some rum

and here it is sanded, it looks pretty.

The black marks are from where I pushed to hard on the router and burnt the wood, no big deal, not bad for my first time with a router and freehand. Like I said about a half hour to knock one out, though that does not included the time to go borrow the router from my neiboubor, have a coffee or two and bs.
I have decieded that I am going to use these wood forms as part of the stator. my wire will be wraped onto this mold and then filled with a bonding resin. Maybe accu-glass as I have some left over.
its not going to take much wire, because I have such speed 1800-2000 rpms, I can use few wraps, and even the mag's can be small. By the time I add up the cost I will be around 100 bucks to build the steel mag disk and stator. ofcourse if I had to pay someone to build this I imagine this would cost 500-600 or so for a one off. so if you remember my cost for that gennie was 150 bucks and if it costs me another 100.00 that will be 250.00 Not bad at all for what should be the worlds most efficient battery bank charger, unless nasa has done one and isnt telling. I am making extra stators as you can see, because once I have one built and can take measurements I can then dial in what I need to do to make a stator for any voltage /current combo I would like, there are guys...the ones with sliderules and such who could calculate out everything to the milliwatt with out having to build one....but i will have to do this the hard way

Now I had company stop by this last weekend, and he said to me " I bought one of thoses gennies like you guy's were buying last year" its in the truck. I said great bring it in and we will replace the cord right now...he brought in a princess auto one same size, he starts telling my how this one has a dc charging feature and such........I am going to be clear, there are others that look simillar, even the engines look the same...THEY are NOT! and as much as I like Princess auto for some things, if it has a princess auto engine on it its crap, crap, just so I am clear its crap! The only engines you will find in my junk pile are Princess auto engines(power fist engines).

Stator is all wired up and cast.

This turned out to be a great way to make a stator....I am going to talk with a company monday about running off a few for me on there cnc table, I think I may put together a windmill kit based on this design for christmas gifts for next year.

you might have noticed, I changed to 18 gauge magnet wire...I just pulled it off that alt I took off, just to show you dont have to buy new wire, and you might be wondering what I cast that stator with? oh wait..maybe not ..this is the same crowd who wouldnt even guess one of 3 reasons that permanent magnet alternator wasnt so popular......

Jan 5th...I just ordered my magnets, found a reasonable price 3.88 per magnet for half inch thick ones with a 50 pound pull strength..so for 12 thats 46.00 dollars, so far the only thing I have had to buy...now I ordered these with about 200 others magnets for other projects..so this is a heavy order and it will have to be ground shipped so I dont expect my mags for 3 weeks or so.

Durabond

Durabond, the dryway compound? ...Good guess..that is outside the traditional..but no...I had a unopened pail of a product called lino paste...it was from 25 or so years back, dont know if they still make it under that name, but it is/was horse glue, a real good use for horses (and goats) imo.

Just thought to use it to show most anything can work, I am building a shower and was using thinset mortor for the floor..I almost used thinset to see how well that would work...lots of things can be made to work, I will try something different with each stator I make.
only time what you use is real important is if your running the stator hot, but I plan not to that with these. If I didnt have something to cast the coils with I could even use it without having the coils cast in place, but how long it would produce power is a guess..without something holding the coil wires tight they will vibrate and over time wear the insulation off and the windings could short together, or break from flexing... its a guess how long that would be but at the low power level I am shooting for it would likely take months.

just got a email back from the magnet company....some of the magnets (like the ones for my windmill kit) were not in stock and my order cant be shipped for 8 weeks, I suspect this means they just placed the order with China now, so if it takes 8 weeks before they ship, and a few more to get to me..it could be 2.5 to 3 months 😥 before I get them..

Good news is China no longer has export quota's on rare earth metals so prices should come down in the future.

I guess the corrosion factor would have to be considered in the filler. What about automotive fibreglass/epoxy?