Rewinding Bafangs?

[bdteakle]

I'm looking for advice on rewinding Bafang 250w hub motors.
For a few years I've been assembling ebikes for neighbours, family members and myself, riding the steep roads of Mount Glorious and Mount Nebo. The long steep climbs are hard on motors, so I now have quite a few burnt out motors I'm keen to repair. I have unwound one motor and noted number and direction of winds, and I can see that these motors (compared to any other electric motor I can think of) would probably be relatively easy to rewind.
I recently asked GreenBikeKit.com if they could supply replacement armatures. They replied that Bafang didn't want to sell them (tho GBK are stocking an increasing range of Bafang parts). So it looks like rewinding is the only option for repair.
Have any of you had any experience with rewinding hub motors, especially Bafangs? I'd be grateful for advice, especially how to insulate the windings from the core, whether to impregnate the windings with a resin, success in getting a durable motor from the effort.
Here's one motor with only one phase with burning.

Other motors are fully cooked, even the insulating card is blackened.
Thanks from Bruce.

 

[heathyoung]

They are a hell of a lot easier to rewind than the larger hub motors. The card and rewinding supplies are easy to get from online, even Jaycar has bits you can use (winding wire etc) - there are a heap of rewinding calculators that only need the number of magnets and stator segments (it's called the stator because it is stationary)

 

[jateureka]

I have one that is totally cooked so bad the hall sensors flop around in the slots. Looks like your #18 wind all the way around & it was still working, although intermittant! This was on a stock controller at 36V.
I haven't seen anything specific for Bafang, but there are some threads with info

rewinding a turnigy http://endless-sphere.com/forums/viewtopic.php?f=30&t=20618
rewinding a H3540 http://endless-sphere.com/forums/viewtopic.php?f=30&t=43781
another hub rewind http://endless-sphere.com/forums/viewtopic.php?f=30&t=34750
effects of winding changes http://endless-sphere.com/forums/viewtopic.php?f=30&t=25940

 

[Samd]

Reckon I have one or two if you want to have a go! I've been calling them consumables for awhile now...

 

[jateureka]

Good motor winding info here when Farfle made his own motor http://www.endless-sphere.com/forums/viewtopic.php?f=30&t=41576&start=100

Photo of motor that was still working under light load and intermittantly under heavier load -totally fried! This thing stank the whole shed out when I cracked the case open... The enamel on the wires got so hot it melted and was flung off onto the inside of motor case.