I thought everyone might like to see these photos of construction of the 4200 mm diameter turbine in Palestine that Noam sent me in July.
Attached please find images of our new 4200 build. You may see the blade jig we had built to speed up the blade make. We first cut it with a band saw than machine it on the jig with a Frazer. You may see the first magnet disk mounted on the frame and the image of the 20 coils 54 turns (2 mm diameter copper), stator ready for casting. Since the metal disks of the magnets are powder baked and the vinyl ester has very good adhesion to the polyurethane powder material, I hope no leaks for moisture will reach the magnets. Also the stainless steel band around the disk is easy to make and make a nice finish. Next magnets batch are going to be Epoxy coated, and I hope this further protection of the magnets will help.
The last time I saw someone use a router jig like that was in 2009 at the Rencontres Creative in France. It’s pretty noisy and dusty. Ingenious though.