Winding the coils

Using the jigsaw to cut plywood pieces for the moulds

Cutting the plywood magnet template

Assembling a rotor mould

Fitting the magnets in the template

Connecting the two stators, one designed for a single rotor and the other for a double rotor

The coils connected and ready for casting

Gluing magnets on the galvanized metal disk using the template

The magnet disk ready for casting

Cutting some fiber glass to reinforce the resin

Casting the two rotor disks

The mould filled with resin

The fiberglass piece is added before closing the lid

After laying a fiber glass piece the coils are placed in the mould

The coil holes are filled with an iron powder and resin mix at a 3:2 ratio

Care is taken not to spill the mix outside the coil holes

The rest of the stator casting is filled with vinylester resin as usual

Care is taken not to blend the two different resin mixtures

A piece of fiber glass is placed on top once all the resin has been poured in

The lid is fastened to the rest of the mould with bolts and nuts