I start with a rough square cut from a steel sheet
This is the cutting jig that holds the rotor and torch
Steel and torch on the jig
The rotor is cut out
The cutoff scraps from the corners of the rough square are used to make gussets - nothing is wasted
Generator rotor after cleaning up the ediges and wire brushing to remove rust scale. It is now ready to be welded to an X-series hub and finished on the lathe to make it perfect. I machine these rotors to within +/-.0015" tolerances
Rotors being drilled for lightening and puller holes
Rotors drilled and ready for hubs
hubs are drilled - one hole is drilled on a different center to provide positive indexing of rotor
rotor is bolted to hub with socket head cap screws
detail showing hub mounted to rotor
rotor on PTO of turbine mainshaft
printed template used to center punch magnet pin locations
rotor ready for magnets after being treated with a special chemical I use that's very similar to the blueing process used on firearms
back side of rotor after being etched and treated with anti-rust coating
Coil winder - pretty crude but it makes beautiful trapezoid coils
