How to Convert a Car Alternator into a High Efficiency Brushless Motor

Step 1: Converting the Alternator

• Objective: Modify a car alternator to turn it into a brushless generator.

1. Disassembly

   • Attempt to disassemble the alternator pulley.
   • Weld a piece of iron between the pulley and the bearing to block the bearing.
   • Successfully disassemble the pulley.
   • Disassemble the rear cover and remove all screws.
   • Remove the brush or carbon support and diode rectifier.
   • Cut diodes to remove diode rectifier.

2. Removing Components

   • Identify and remove three coil connections.
   • Remove screws from alternator casing; open housing.
   • Extract the copper winding and shaft.

3. Preparing the Rotor

   • Cut all iron parts from the rotor.
   • Smooth cut iron surface using a bench drill.
   • Wrap insulating tape around the rotor to flatten the surface for sticking magnets.

4. Magnet Installation

   • Use neodymium magnets, gluing on areas where iron was cut.
   • Glue with Instant Adhesive (Cyanoacrylate); use electrical tape until adhesive dries.
   • Ensure magnets are paired, with South Poles facing outwards.
   • Repeat process for North Pole magnets on the opposite side.

5. Epoxy Resin Reinforcement

   • Use a plastic bottle and insulating tape to create a container around the rotor.
   • Seal one end with hot silicone.
   • Prepare and fill with Epoxy Resin; let dry for 24 hours.
   • Remove insulating tape and plastic container.
   • Smooth the surface using a bench drill.

6. Reassembly

   • Weld three cables to coil connections; use heat shrink insulation.
   • Reinstall rear bearing of the shaft.
   • Mount copper winding on rear cover of casing.
   • Insert rotor shaft and reassemble front cover with screws.
   • Fix an electrical strip and connect cables.
   • Attach the pulley on the shaft.

7. Result

   • Finished product: 10,000W Brushless Electric Generator.

Step 2: Single-Phase Motor Coupling

• Objective: Manufacture motor support and couple with the generator.

1. Building the Support

   • Create motor support.
   • Assemble motor pulley.
   • Manufacture support for the Brushless Electric Generator using wood.

2. Assembly

   • Screw together motor and generator.
   • Install the transmission belt.
   • Make all necessary electrical connections.

3. Outcome

   • Operational Free Power Generator.

Step 3: Testing the Perpetual Energy Generator

1. Initial Setup
   • Connect various electrical devices.
   • Pull starter cable to generate initial energy for the motor.
   • Motor continues moving the generator, creating a self-sustaining electrical system.
   • Produces 220 volts and powers electrical appliances.

Final Thoughts

• The generator allows for the generation of 220 volts and 10,000 watts of power.
• Encouragement to like, share, and support the video to join the energy revolution.