7/22/2018 - Finished & added base/frame that bolts to stator. Posted updated diagrams
UPDATED STL FILES: Realized that I had the bearings in the wrong place. Should be in the stator not the 2 rotors. Updated both models and stator will accept 2 bearings to support the weight. Also added some spacers around the shaft. If using 2 rotors ... one on either side ... make sure the poles are aligned with each other
Marked as a work in progress but ready to print. Fact is that I cannot afford the huge N52 magnets (20 of them in all) to build this yet. I may build it using only one rotor at first and add the second rotor at a later time. I'd expect this to generate a fair amount of power.
This axial flux generator is huge, almost 11 inches diameter. Magnets are N52 measuring 2 x 1 x 0.5 inches / 52 x 26 x 13mm with a #8 center screw hole for mounting.
Stator accepts the included coil formers and tracks in the stator keeps the wiring neat. I'd suggest wiring all in series for high voltage @ low RPM's but feel free to wind it the way you'd like. Will rotate very freely with virtually no drag.
For wire I suggest #18 or #16 enameled wire. If desired the coil can be removed from the former but should work just fine if left in the former ... plus ensures a tight fit.
The magnets can be found on amazon and are about $14 each. Also, if you decide to exclude the plastic coil formers and place only the coil itself into the slots, consider pouring resin to greatly extend the life of the stator. i.e essentially using the stator print as a cast
Magnets - https://www.amazon.com/CMS-Neodymium-Countersunk-Turbine-Projects/dp/B01N8RTOJP/ref=sr_1_5?ie=UTF8&qid=1532541679&sr=8-5&keywords=bar+magnets+wind&dpID=41msOLFWFML&preST=_SX342_QL70_&dpSrc=srch
I REALLY hope someone will make one of these. I can print the parts and prepare the coils but it will be a while before I have the $$$ for 16 magnets !!!
To insert the bearings and shaft use a hair dryer to slightly warm up the plastic ... then use a rubber mallet or press to insert for a very tight fit