Winding coils with four wires at hand

Inserting the temperature sensor in one of the coils

The coils and temperature sensor after winding

All coils wound, placed in the mould and ready for connecting

The sensor cable going round the coils towards the three power transmission wires of the stator

Connecting the coils in three phases and in star connection

Making the stator and rotor moulds

The stator coils connected and ready for casting

Cutting out the magnet jig and making sure that the magnets fit in the holes

Placing neodymium magnets around the magnet disks

Magnet disk rotor ready for casting

The metal frame which supports the bearing hub and the stator

The finished rotor disk ready for assembly

The finished stator ready for assembly

Assembling the generator on the test bench base

Lowering the front rotor disk with the jacking rods

The 5kW generator assembled and fastened on its test bench base

The test bench ready for driving the generator with a DC motor drive while connected to a 48VDC battery bank