Alternator Rotor Machining

johnm said:

But is it perfectly central to the shaft.

As I said above mine clocked uo on a lath showed it needed a 5 thou skim to centralise.

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That seems to be alot, it might even cause some vibration?

...yet all this stuff was originally designed mass produced, to be slapped together & WORK.

My stator has .008 on the tightest side. Clearance enough. Charges fine. Doesn't rub. Doesn't go on fire

concours said:

...yet all this stuff was originally designed mass produced, to be slapped together & WORK.

My stator has .008 on the tightest side. Clearance enough. Charges fine. Doesn't rub. Doesn't go on fire

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So what’s your theory as to why modern pattern ones have such a high failure rate ?

Fast Eddie said:

So what’s your theory as to why modern pattern ones have such a high failure rate ?

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I would think that poorly coated wire is being wound, and or poor procedures used.
If I was needing to fit a new one, I would test it with my megohmmeter before fitting it.

Given the failures observed, THEY ALL should be megged, batches on the shelf, all of it.