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**sajjt** · 10-26-2011, 07:50 AM

Originally posted by Jeanie View Post

plz see the pic , the only thing that the tiny 1 mm scratch will touch is other wire surrounding it . should i apply varnish on it to correct it ? see the small scrathc on last turn on pole

I think there's some confusion,I was referring to the scratches if u make in the outer layer which can be taken care of by the varnish and applying varnish, it should be applied once the winding is over on all poles. U've done only 7 turns so remove that coil like Nano suggested and try to make tight and neat turns as much as possible, ur goal is max turns in a neat manner say something not less than 70 turns. More u wind, more robust in low rpms, so do that in a neat manner without leaving any space. I still remember the days I tried this circus, I've done it in a stretch but my fingers were aching for the whole day due to this. It needs some practice and most important is patience to get it done properly, so do some rehearsal with that. Like Nano said if u wind it with spaces in between, the next layers will be worse than the first one with less turns on each layer resulting less output from the coil.

@ Nano,

Welcome back mate

**NANOtechnology** · 10-26-2011, 11:24 AM

Well, its good to be back, thanks saj..

Jeanie remember, after a few thousand kms of running and vigorous oil circulation at temperatures upto 80 degree Celsius in the engine, the enameled copper wire tends to melt the outer covering (the one that you scratched) so basically when this happens, it will turn into 1 big lump of copper winded on a pole, hence to avoid this or to delay this to a few lac kms, varnish is used...

Take it easy, if possible do 1 pole on 1 day, but make sure its done in a very neat manner, no matter how experienced you are or if have done it for the first time, after 1 or 2 poles you tend to do it in a very neat manner.
Try finishing a pole, the next one will be better, and the one after that will be even much better, all the best...

@ saj and others..

Hey just to let you know, I've tried an experiment using 18 guage wire on an 8 pole stator, it gives 14.5 volts at 3.5k rpm, just as good as 19 guage...

But its difficult to wind 18 guage, too much of stress on the fingers, 19 looks like a piece of cake....

**Jeanie** · 10-26-2011, 12:08 PM

thanks guys , restarted and did 3 poles today . finger aching badly ! btw what type of varnish to buy ?? wood varnish ? or some special high temperature type ? i measure the wire i had wined on my first pole it was around 10 feet . if i wind say 10 or 9 feet on all 8 poles what approx ampere current will bike make at 2 k rpm and 4 k rpm , 6 k rpm , 8 k rpm. any ideas ?

**sajjt** · 10-26-2011, 01:20 PM

Originally posted by Jeanie View Post

thanks guys , restarted and did 3 poles today . finger aching badly ! btw what type of varnish to buy ?? wood varnish ? or some special high temperature type ? i measure the wire i had wined on my first pole it was around 10 feet . if i wind say 10 or 9 feet on all 8 poles what approx ampere current will bike make at 2 k rpm and 4 k rpm , 6 k rpm , 8 k rpm. any ideas ?

U need to buy the winding varnish from the shop where u got the copper element. Drip it to each poles like garnishing the salads

till it oozes out to the bottom side and keep it there for getting dried within 1-2 hr. For wet type coils doesn't required this treatment IIRC if the winding is done properly.

Output will vary with the no of turns and not in length it also depends on neat windings, stator core specs, insulation of the element etc.

**Jeanie** · 10-26-2011, 02:49 PM

Originally posted by sajjt View Post

U need to buy the winding varnish from the shop where u got the copper element. Drip it to each poles like garnishing the salads

till it oozes out to the bottom side and keep it there for getting dried within 1-2 hr. For wet type coils doesn't required this treatment IIRC if the winding is done properly.

Output will vary with the no of turns and not in length it also depends on neat windings, stator core specs, insulation of the element etc.

ok suppose keeping a conservative figure of 50 circles on each pole x 8 poles . what will be approx output in amps /watts in 2k ,5k ,8 k rpm .

**ATHUL4R** · 10-26-2011, 04:29 PM

please post the photos after winding step by step and side by side. I need to wind it next month (self doing). i am now learning by reading this thread every day :-).

is our full warranty will go with this mod?
or only electrical warranty ? please kindly explain. mine is only 2 months old CBZ XTREME.

is the 8 pole is interconnected ?

**sajjt** · 10-26-2011, 06:47 PM

Originally posted by Jeanie View Post

ok suppose keeping a conservative figure of 50 circles on each pole x 8 poles . what will be approx output in amps /watts in 2k ,5k ,8 k rpm .

As I said earlier, it depends on the quality of work u've rendered mostly, stator design, magnet power etc. I can't give u any figures just by predicting, I've given the max u can expect from a 8 pole decently winded ie; 10-12A. I think anything beyond that will be sheer greediness which can only a dream.

BTW, 50 turns will be a problem in low rpms as the voltage anything less than 12 will not be pushed to the battery where ur battery may get stressed, try to push few more turns.

**Jeanie** · 10-26-2011, 07:51 PM

Originally posted by sajjt View Post

As I said earlier, it depends on the quality of work u've rendered mostly, stator design, magnet power etc. I can't give u any figures just by predicting, I've given the max u can expect from a 8 pole decently winded ie; 10-12A. I think anything beyond that will be sheer greediness which can only a dream.

BTW, 50 turns will be a problem in low rpms as the voltage anything less than 12 will not be pushed to the battery where ur battery may get stressed, try to push few more turns.

also 1 more query . i winded 5 poles today and most i guess have around 60 turns but 1 pole i kinda messed up and have only around 50 turns on it . so like will output be less than 12 volts at 1-2 k rpm ? also can u tell me what if i had used 20 gauge wire instead of 19 . i guess winding will be much easier on 20 and even beginner can easily put in a lot of number of coils . can u tell advantage disadvntg of 19 g vs 20 ??

@ ATHUL4R - will post some pics when done , but i suggest u try finding a used spare coil of ur bike from service centre etc. on which u can practice or atleast look at it . only seeing thing in person u will understand better

**ATHUL4R** · 10-26-2011, 11:31 PM

Originally posted by Jeanie View Post

also 1 more query . i winded 5 poles today and most i guess have around 60 turns but 1 pole i kinda messed up and have only around 50 turns on it . so like will output be less than 12 volts at 1-2 k rpm ? also can u tell me what if i had used 20 gauge wire instead of 19 . i guess winding will be much easier on 20 and even beginner can easily put in a lot of number of coils . can u tell advantage disadvntg of 19 g vs 20 ??

@ ATHUL4R - will post some pics when done , but i suggest u try finding a used spare coil of ur bike from service centre etc. on which u can practice or atleast look at it . only seeing thing in person u will understand better

can you tell me rough price of used coil?
i think 20 is thicker that 19 and i dont think that we can wind 60+ round , correct me if i am wrong.

**drvmtm** · 10-27-2011, 03:01 AM

great initiative fellas,good going.

rewiniding is an art,its your exam of patience.do it slowly and neatly.dosent need to be all poles equal,remeber its the total wire inserted in the coil that matters as its a single phase continuous coil .electrical vernish is diff then wood vernish,try fan winding shops for luck if u dont get,the cover that area with superglue. 19 is thicker then 20 but stick to 19.the output is better,a good balance in voltage and amp in low rpm,20 is thin but u have to wind too much to produce enough amps.

**ATHUL4R** · 10-27-2011, 08:47 AM

Nice help DR. THANKS :-)

with about 60+ turns can i install a twin 55w/60w halogen in 12v 7ah batter?

**sajjt** · 10-27-2011, 01:20 PM

Originally posted by ATHUL4R View Post

please post the photos after winding step by step and side by side. I need to wind it next month (self doing). i am now learning by reading this thread every day :-).

is our full warranty will go with this mod?
or only electrical warranty ? please kindly explain. mine is only 2 months old CBZ XTREME.

is the 8 pole is interconnected ?

Why do u want to fiddle with the warranty by rewinding and swapping the RR? Its better to wait for the warranty period expiry for ur peace of mind.

Yes, its all the same wire without any joints in all poles.

Originally posted by Jeanie View Post

also 1 more query . i winded 5 poles today and most i guess have around 60 turns but 1 pole i kinda messed up and have only around 50 turns on it . so like will output be less than 12 volts at 1-2 k rpm ? also can u tell me what if i had used 20 gauge wire instead of 19 . i guess winding will be much easier on 20 and even beginner can easily put in a lot of number of coils . can u tell advantage disadvntg of 19 g vs 20 ??

I guess u got the points from Doc's post.

Hey Doc, that sounds funny, hope u enjoy the time

I still remember the day I went along with my wife for the scanning and that's really exciting to see ur baby's activities before it comes out

.

I think we should stress to the no of turns per pole than the length in every coil as its the no of turns makes the difference than the length AFAIK.

**ATHUL4R** · 10-27-2011, 05:25 PM

Originally posted by sajjt View Post

Why do u want to fiddle with the warranty by rewinding and swapping the RR? Its better to wait for the warranty period expiry for ur peace of mind.

Yes, its all the same wire without any joints in all poles.

so i need to wait till warranty expiry its 545 days i think

. and with these useless HH SVC guys (my area JCT MOTORS) really not a single owner is satisfied with their service.

**Jeanie** · 10-27-2011, 10:03 PM

Originally posted by ATHUL4R View Post

so i need to wait till warranty expiry its 545 days i think

. and with these useless HH SVC guys (my area JCT MOTORS) really not a single owner is satisfied with their service.

on most warranty issues they will not open ur engine to find out if coil is different

i think its safe to do the mod

**sajjt** · 10-27-2011, 10:51 PM

Originally posted by Jeanie View Post

on most warranty issues they will not open ur engine to find out if coil is different

i think its safe to do the mod

Too smart

but do u think they don't even know the RR swap too? APE RR is not just a P&P for a AC+DC bike unless u make use of a spare HH stock connector to connect this so that at any point of time u can go back to stock but the question is how will u manage to get one?

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