That whole iron question is the big one in my head also. But untill I can get my mits on some flat copper in a apropriate size (without breaking my wallet) I am just going to play with cores & coil configs. I am anxious to see how a true ironless motor performs in testing though. I may have a go at building a rolling shear & cutting my own flat stock.( I see that as an advantage in an ironless design)
As for drill wander, it sucks! if anyone ever asks what is the most used tool in my shop I have to say my Drill doctor. I have the cheapest version in the line & the thing just rocks!http://www.drilldoctor.com/pilot.asp?pg=user-guides
I bought mine at menards on sale for $50 & I use it all the time. it just works & a as a pro woodworker having sharp tools is a matter of pride.
love the drill doctor . ive learned that dull tools are a waste of time . and same here , i used up one bit doctor and had to replace it for the worn stone. comes in real handy when you need a short drill bit , just cut to size and resharpen. long long ago i used to able to sharpen one by hand but id bet that skill is buried beneath a few years of beers now.
as for some copper i better get a good idea of what you gents seek there. i got that rotor blank (the nice round one) from my local metal mart for $2.50 . they have bins with all the off cuts and i noticed varying sizes of copper flat bar . IF im right they have a size that would be great for you coils and as ive done some work for the manager of that outlet i can usually get offcuts on the cheap or free.
after sleeping on it and reading the posts you gents put up last night ill start by using rotor #1 with a stock alternator stator , local auto electric shop will do me a custom rewind on it for $50 including the wire. SOLD
im still going to make an ironless version and if i get my way ill have 2 rotors and 2 stators all of differing makup . should be fun to play with.
At entry level design stages, the motor will be helped by iron at all points. You gotta really have your design tits-on before ironless starts to help at any RPM point.
Thanks LFP . kinda where i was heading i think, i was feeling it was a little to early to jump right into ironless cores unless you folks tell me its a hands down winner . seeing i can get that stator rewound for that price (less than i was about to pay for wire to diy) ill give that a go . the fella that runs the auto electric shop is willing to sell me extra wire for my weird science and ill give the ironless a shot this week . But ya im thinkin out of the gate ill use rusty ol iron.
And kim . id love your sheet
but no worries bro . something tells me the shipping would be more than we could stomach AND i think i may be on to a good lead locally. stay tuned.
i may even have it spinning this week coming up.
M.E.N.S ex pres and charter member.