Once the match is verified, we know that we will have a solid mechanical mount for the generator when it is fully assembled.  This is extremely important, as vibration can cause the mounting hardware to work back and forth in the holes and wallow them out.  This will result in a failure that will probably wreck the system.

The shaft for the generator is now assembled with its components.  I machined a pair of rotor discs made of HDPE (high density polyethylene) because is is lightweight and tough.  It is also very uniform in density throughout and has little problem being balanced to rotate properly without vibration.  Here you can see the steel shaft, the two aluminum rings, and the two HDPE discs.  Now we only need to mount the permanent supermagnets on plates to create a permanent magnetic field for the generator.  This will eliminate the need to power field windings- we simply eliminate them entirely.  Since we have a permanent field, we will not need to create one using electrical power (that should be used to power other things, such as appliances).

Now the question is, how do you mount all those magnets?  Here we have used flat mild steel sheet metal as the base for the magnets and placed them so each set of three has the same poles facing out.  Each strip of magnets is all North or all South poles.  The sets of pole alternate over the whole rotor so that the stator windings will get alternating N-S-N-S fields applied as the rotor turns.  In other words, the strips alternate poles from strip to strip.  Here is the rotor with the bare metal strips, ready for magnets.

The magnets are next.  Here they are mounted on the strips, temporarily held in place with superglue.  It is a fight to get the poles to line up properly and stay in place, as the magnets are bucking each other during assembly.  However, we managed to keep them in place and use a dot of standard cyanoacrylate glue to hold them there.

After gluing the magnets onto the strips (and testing to make certain the poles alternate) the whole assembly was wrapped in Tyvek plastic, a very tough material, and then coated with marine epoxy to hold everything in place.

MORE TO COME AS THE SYSTEM IS COMPLETED