Upon receiving the hub motor, the first thing I wanted to do was find out how strong, the magnets in the casing really were. My one answer is, they are terribly strong.
The first thing that needed to be done with the shorted stator was to take all the existing windings out. All told, it took about eight to nine hours of taking the wires out of the stator. The one thing that put me back was how much power these things can produce despite being so small.
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The first phase, I took out of the motor, I made sure to measure how long it was. I did this to guess how much wire it would take me to fully wind each phase. Of course, I added an extra two to three feet because I knew I was not as skilled at winding than the people who wind these motors. In the time it took me to wind one quarter of a phase, these ladies wound about one or two motors.
Victory picture of the unwound stator. What a sense of accomplishment that 8 hours or so of work has finally payed off. Now the winding can begin.
The dimensions of the stator teeth. I used these to cut the nomex paper to the right dimensions.
To help keep the wires from rubbing up against the bare stator, I used nomex paper. Nomex paper, is the toughest paper I have ever come in contact with. This stuff is almost indestructible and will give you the nastiest paper cut known to man. This stuff is rough and tough and will not wear out so easily. Which is why I chose to use the paper to help keep my project from shorting out anytime soon.
The stator all filled with nomex paper and ready for winding.
After filling in the stator with nomex paper, I realized it did not make sense to wind the stator with the nomex paper sitting in the stator teeth, so I took out all the nomex paper that was not going to be immediately wound with the phase wires.
I realized, it was taking too much time to wind that stator with all the wires at once, so I wound the motor one strand of wire at a time for each phase.
I used this paper to make sure I wound each stator tooth the correct number of times. One incorrectly wound stator would render the motor completely useless.
Just a random picture I took of the partially wound stator
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Hub Motor Rewind
I was having some speed anxiety with my bike with my previous motor and the motor that was wound for slower speed was a little too slow for me. My solution was to buy a motor that someone had shorted for next to nothing, gut the stator, and wind it so the motor would deliver the speed that was right in between the high speed wound motor and the low speed wound motor.
Long story short, this project was eating all the free time I had so I had to stop the project and keep up my studying for community college