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The next step is winding the coils.

We wound one, tested it, and found we needed more


voltage, so we ended up using 2 coils. Each coil is 400 turns of #30AWG enameled
magnet wire. We used a simple hand-held coil winder, and made up a new center insert to
get the coils the right size. The inner hole of the coil should be about the same size as
each magnet you are using. You could also wind the coils around a tube that's the right
size, but the elliptical coil shape we got by using a winder performs a little better, and the
tapered form in the middle makes it easier to get the finished coil off of the winder. The
important thing is to pack the wire in there as evenly and tightly as possible.....the
finished coils should be about 1/4 inch thick, with each leg of the coil about 1/4 inch wide
and the center hole matching the magnet size. Here's a detail of how we built the winder:

Here's DanB winding a coil. Notice how the spool of magnet wire is on a pin in the vise
to permit easy feeding. We also wax the winder form with crayons so superglue won't
stick to it...makes it easier to remove the finished coil. Leave a big tail on both ends of the
magnet wire.
Once you get 400 turns on the coil, twist the leads together so the coil won't unwind, and
drip superglue into the coils. We then hit it with accelerator to speed the drying time.
Then disassemble the winder and carefully remove the coil. Hit it with more superglue if
it wants to come apart on you. At this point you can even spin the wheel and hold the coil
up near it by hand. In our first test we showed about 1.2 volts AC when doing this. That
told us we needed another coil, which will double the voltage when hooked in series and
in phase with the first coil. You'll need to strip the wire ends with sandpaper, razor blade,
or knife before connecting.

At this point you can mount the first coil. We simple glued it to a small block of wood
and glued this to the frame. Get the coil as close to the rotating magnet ring as possible
without it touching. We ended up with a big airgap here due to the wobbly motion of the
wheel....about 1/8 inch. But the big magnets make up for this tolerance flaw. You should
get an AC voltage reading now from the mounted coil when you spin the wheel. We
could get more power out of the coil by mounting laminates or another magnet rotor
behind them, like we do when building wind turbine alternators. But we decided that
Skippy probably wouldn't care either way, and one side of the magnetic circuit open
made for much easier construction.