Decogging a Fisher and Paykel SmartDrive

DISCLAIMER:
This post involves decogging a Fisher and Paykel Smartdrive motor, with the use of power tools, welders and human strength. If you're attempting this as well, I take no responsibility for injuries that may greet you.

Following along with my plans of making a wind turbine, this post shows how I went about decogging the motors. Reading through The Back Shed articles, the two main ways of decogging a Fisher and Paykel Smartdrive motor seem to be
1. grinding off the corners of the stator poles
2. twisting the stator poles.
For the sake of learning, I went with trying both.

Making a SmartDrive decogging tool

This post requires the use of power tools and welders so if you are following this, don't be stupid, and make sure you know how to handle the tools as well as protect yourself from them. I take no responsibility for injuries that may come about from this post.

EDIT 10/10/12: Found more pictures.


Making this decogging tool requires access to a welder, so if you don't own or have access to a welder (be it through friends or work), you will have to think up another way. If you're really willing you could make your own welder out of microwaves. Milling machines can also be used to make the tool as seen on The Back Shed, credit to Jarbar for making the tool and it's much prettier than my own (see right).

Homemade Macbook mini-DVI to VGA adapter

With Apple's need to make things as far away from normal as possible, I found myself with two Macbook's with smashed screens. To fix those would have cost $200+, so that was out of the question. I could have also brought an adapter for them, but that takes all the fun out of it!

Here's how I made the mini DVI to VGA adapter using some old ribbon cables used for connecting PCB's together (not IDE type ribbon cable), and an even older mini VGA adapter for the VGA port, and don't forget the 10K resistor!

Babington oil burner

With most projects, they have to start somewhere. One day I hope to make a foundry for melting and casting metal, and the logical place to start was the fire. After an amount of research and parent nagging the babington oil burner build was commenced... Here's the not very well documented build log for it.

ZVS Flyback Driver

Well, on route to one of my many other projects I needed a form of ignitor, couldn't get my hands on any neon sign transformers (the three local sign places either didn't have any, or wanted $100 a piece), and MOT's were too low voltage for my needs. My attempts at winding a step up transformer also resulted in a step down transformer due to lack of wire. Here's how I managed to create a ZVS driver and not electrocute myself in the process!