1. Dismiss Notice
  2. Dismiss Notice
  3. Hey Facebook people... We've created a group for XS650.com members to connect. Check it out!
    Dismiss Notice

Rotor Winding Tooling

Discussion in 'The Garage' started by Jim, Jul 22, 2018.

  1. MaxPete

    MaxPete Life with Lucille...I suggest, she decides. Top Contributor XS650.com Supporter

    Use of the term “fine tune” in relation to XS650 engine vibration is NOT approved.

    Tee hee!
    E2713B54-A5DF-4582-B3EA-CA4E36F4521F.gif
     
    Last edited: Mar 11, 2019
    Paul Sutton, GLJ, 59Tebo and 4 others like this.
  2. kshansen

    kshansen XS650 Junkie Top Contributor

    665
    1,613
    143
    Hey now! Even Jimi Hendrix had to "fine tune" his guitar to play this:
     
    59Tebo and Jim like this.
  3. Jim

    Jim The thrill of victory and da agony of da feet. Top Contributor XS650.com Supporter

    Last bit of tooling.... I swear...

    OK... this bit isn't really necessary, but I did it anyway. I picked up a 12V 5A power supply. Fastened it to the timing mark checker....

    1.jpg

    On the side of it I attached a .010" feeler gauge....

    2.jpg

    Rigged up a probe of sorts and when you touch the probe to the two slip rings, it pulls the feeler onto the rotor. Voila... magnetism. These are actually pretty strong little rotors. I held an 11/16" combination wrench (that weighs a half a pound) about an inch away from it and it snatched it out of my hand. Kinda startled me... :yikes:

    3.jpg

    I'm gonna make a proper probe for it and add a switch. The main reason I did this so I can try to get an idea of the longevity. I'm going to take the out of round rotor and run it along the lines of 2 hrs. on... 15 min. off and then back on again.... simulate a cross country. 100 miles, stop for gas and a pee, 100 miles... gas and pee.... 100 miles.... We'll see how it does.
     
    Last edited: Mar 12, 2019
  4. MaxPete

    MaxPete Life with Lucille...I suggest, she decides. Top Contributor XS650.com Supporter

    Thorough, thorough, thorough.....
     
  5. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    30 watts, for 2 hours?
    Can you rig a temp gauge to it?
     
    Paul Sutton, Jim and MaxPete like this.
  6. Paul Sutton

    Paul Sutton Buckhorn Gang Member Top Contributor

    Watts = Current Squared x Resistance. I always wondered what that was useful for.
     
    MaxPete, MrBultaco and Jim like this.
  7. kshansen

    kshansen XS650 Junkie Top Contributor

    665
    1,613
    143
    When all these rebuild and test jigs are finalized Jim needs to do a photo shoot of them all lined up. Not just a well thought out group of tooling but also an impressive bit of wood working art!
     
  8. mrtwowheel

    mrtwowheel Honda Etched On Brain Top Contributor

    Endurance tests in the desert and Siberia?

    Scott
     
    Paul Sutton and Jim like this.
  9. Paul Sutton

    Paul Sutton Buckhorn Gang Member Top Contributor

    When you switch off the current to the rotor there will be an induced reverse current. My experience with energizing my rotor last year showed that the power should be switched off rather than remove the contacts from the slip rings. Removing the wires from the rings caused small arc burns on the copper. Also, you may need to fit a diode across the power supply to protect against induced voltage spikes. But .....

    .... I am guessing you have though off this because you mention about adding a switch.
     
    TwoManyXS1Bs, MaxPete and Jim like this.
  10. Jim

    Jim The thrill of victory and da agony of da feet. Top Contributor XS650.com Supporter

    254___thumbs-up-emoji.png
     
  11. Jim

    Jim The thrill of victory and da agony of da feet. Top Contributor XS650.com Supporter

    I can now....
    15 bucks at Amazon. Gets great reviews.

    IMG_20190315_124125.jpg
     
    TwoManyXS1Bs, GLJ, Mailman and 2 others like this.
  12. MaxPete

    MaxPete Life with Lucille...I suggest, she decides. Top Contributor XS650.com Supporter

    That tooling you've built looks like furniture Jim - beautifully done.

    Pete
     
    TwoManyXS1Bs, Mailman and Jim like this.
  13. kshansen

    kshansen XS650 Junkie Top Contributor

    665
    1,613
    143
    Jim I wish I could remember what the company I worked for paid for the non-contact thermometer many years ago! I have to think it was somewhere north of $500.00 maybe closer to $1,000.00. I have though about one like your's or the ones Harbor Fright sells for around that same price. At those prices if it only works for a couple projects it would be worth the price.

    How about a link to that one so we can get one too?
     
    TwoManyXS1Bs, Jim and Mailman like this.
  14. MaxPete

    MaxPete Life with Lucille...I suggest, she decides. Top Contributor XS650.com Supporter

    .....aaaaannnnnddddddd.....<drum roll please>............coming soon to a cranky old 1976 XS650C near you.....

    TA DA!!! one of the very first production JimRotors.

    I received the rotor, very carefully packaged, the other day and have finally unboxed it. All I can say is - wow - this is craftsmanship.
    What a beautifully re-made part. Every surface is clean as a whistle, the epoxy potting is neat and tidy and the tiny winding connections are perfect.

    I can't wait to get out into the DCW and install it on Lucille. I will report once that task is at-hand with photos and a description of the install.
    Thanks Jim!
    Pete

    IMG_2430.jpg
    IMG_2431.jpg
    IMG_2429.jpg
     
    59Tebo, TwoManyXS1Bs, gggGary and 4 others like this.
  15. Jim

    Jim The thrill of victory and da agony of da feet. Top Contributor XS650.com Supporter

    Here ya go Ken.

    I'm writing up the ad for the rewinds right now. Just went through this thread to see if I missed anything, so.... a few clarifications....
    I'm using JB Weld to epoxy the coils in. At a 500° rating, it should work just fine. The original epoxy I wanted to use turned out to be more like a potting compound... more of a rubbery substance. I decided not to risk it at the centrifugal forces we'll be pulling with these rotors.

    Also not mentioned yet, when all testing is done, I give the rotor 2 coats of hi-temp clear paint. Of course.... my OCD affliction forced me to make a special tool to protect the rotors taper....:rolleyes:

    IMG_20190315_145521.jpg
     
    59Tebo, TwoManyXS1Bs, gggGary and 6 others like this.
  16. MaxPete

    MaxPete Life with Lucille...I suggest, she decides. Top Contributor XS650.com Supporter

    YUP - and that OCD approach to every single teeny tiny thing is evident everywhere on the actual part folks.

    If you need an alternator rotor to get / keep your XS650 running.....see Jim about it.

    Pete
     
  17. Mailman

    Mailman Hardly a Guru Top Contributor

    Hey now! That’s super nice! Pete you lucky duck!
    Great work Jim, after all the effort you put into this, it’s nice to see you going into production.
    Pete, does yours have the Band of Brothers logo? :cool:
    9866138C-64D0-4E21-B219-D07B148CE3C6.jpeg
     
  18. MaxPete

    MaxPete Life with Lucille...I suggest, she decides. Top Contributor XS650.com Supporter

    Oh yes - its right there but its very teeny tiny.....;)
     
  19. Jim

    Jim The thrill of victory and da agony of da feet. Top Contributor XS650.com Supporter

  20. GLJ

    GLJ Ran through life like my hair was on fire 650 time Top Contributor

    Jim what was the temperature of the rotor after full fielding it for 2 hours?
    Just a thought you might want to use a power supply that can be adjusted to 15 volts and see what the temp is then. Something else that might be interesting is to check amp flow on yours compared to OEM.
     

Share This Page