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Its pretty surprising what can be done with hand tools such as a file if you are slow and deliberate. Since the balance is critical, especially with the 3600 RPM motor, that's why I suggest a milling machine to get the accuracy of depth and position. If a milling machine is not available, another possibility is to use a vertical belt sander with a coarse grit sanding belt. Steve White Cedar Rapids, Iowa ----- Original Message ----- From: "Lux, Jim" <jim@xxxxxxxxxxxxx> To: tesla@xxxxxxxxxx Sent: Tuesday, February 16, 2021 9:49:15 AM Subject: Re: [TCML] sync motor On 2/16/21 7:37 AM, Tedd Dillard wrote: > Thank you Steve I also have that information and am planning on building > one that way. I was looking for feedback on performance as I have also > heard about difficulties. I am glad to hear from someone that has actual > satisfactory experience with the design. > Thanks > Teddy > > On Tue, Feb 16, 2021, 10:27 AM Steve White <steve.white1@xxxxxxxxx> wrote: > >> I have a synchronous motor made that way and it works great. It has two >> flats machined 180 degrees apart. You really need a milling machine to cut >> the flats. My motor started as a standard 1/2 HP 3550 RPM induction motor. >> For a 1750 RPM induction motor as a starting point you need to cut 4 flats >> spaced 90 degrees apart. There are some guidelines buried in the archives >> about how deep and where to make the cuts. I actually have some PDF and JPG >> files of the guidelines but since we can't attach files I can't post them >> on this board. I didn't create these files. These are files that I have >> collected from various sources over the years. If you supply your E-Mail >> address I can send them to you. >> >> Steve White >> Cedar Rapids, Iowa There was a LOT of discussion about this on the list, say, 10 years ago? There are some folks who actually did the flats *by hand* with a file, and it worked. googling "site:pupman.com flats sync" turns up some hits.. https://pupman.com/listarchives/2005/Apr/msg00793.html https://www.pupman.com/listarchives/2000/November/msg00356.html https://pupman.com/listarchives/2001/July/msg00168.html https://www.pupman.com/listarchives/2002/February/msg00621.html _______________________________________________ Tesla mailing list Tesla@xxxxxxxxxxxxxxxxxx https://www.pupman.com/mailman/listinfo/tesla _______________________________________________ Tesla mailing list Tesla@xxxxxxxxxxxxxxxxxx https://www.pupman.com/mailman/listinfo/tesla