How To Make RC Brushless Motors

Wrap the Stator

• 1

  Wind the AWG wire around each of the nine teeth around the stator. Find the small notch on the inner bearing to identify the first tooth where you will start winding. Leave four inches of distance from one end of the wire, then begin wrapping it around the tooth. Begin the wrapping near the inner circle (the hub), then work your way out to the outer edge of the tooth (called the hammerhead). You should fit nine coils over the distance of the tooth; continue to layer the wire over itself until you have reached the number of turns you prefer.

• 2

  Skip two teeth from the first one you wrapped, then wrap that next tooth with the same wire. Wrap it with the same number of coils, then skip another two teeth and wrap that third tooth of this first phase in a similar manner (a phase consists of three teeth out of this nine-tooth stator).

• 3

  Repeat Steps 1 and 2 for the second and third phase of this stator. Start the second phase from the first tooth directly adjacent (clockwise) to the tooth that began the first phase. Start the third phase two teeth (clockwise) from the initial tooth of the first phase. Wrap all the teeth with an identical number of coils, then orient all the ends of the wires in one direction (this will be considered the bottom of the stator).

Magnet Installation

• 4

  Place a black dot with the permanent marker on one side of the N45 magnets to identify the magnetic north side. Install the first magnet (with the dot facing out) into the can in alignment with one of the three nubs (placed their to help orientate the magnets). Place a north-facing magnate over each of the other two orientation nubs, then touch the edge of the three magnets with a small amount of CA glue to secure them in position.

• 5

  Install three more north-facing magnets directly opposite the initial three you installed in Step 1. Make sure all of the magnets are at the same height within the bell, then apply a small amount of CA glue to each.

• 6

  Install six south-facing magnets between the north-facing magnets by orienting them with the black dot facing inward. Place toothpicks between the north and south magnets to prevent them from moving, then apply a small amount of CA glue to each of the six south-facing magnets.

Final Assembly

• 7

  Insert the shaft into the rotor hole by sliding the shorter side of the shaft into the rotor. Use the bearing holder assembly to align the shaft during installation. Attach the stator to the bearing holder with a small amount of CA glue.

• 8

  Connect the six ends of the wires (wound around the stator teeth) into two groups of three. Twist the beginning of three wires together (one per phase), then the end of the three wires together (one per phase).

• 9

  Wrap the length of them with heat shrink wrap tubing. Leave a distance of 1/8 of an inch on the very end of the two groups to allow connection to the electronic speed control. Apply a small amount of solder to the exposed tip to connect the wires.