Using a Lathe for Fitting Steel Hub to Rotor

I have found a micro lathe essential for this project. Many times you will need to precisely drill holes and line up rotating objects. I have used the lathe to fabricate bushings that have allowed me to center objects. My microlathe is from Sherline.

I used the lathe because I needed a way to transfer the wind energy to the magnetic rotor.  I thought about having the blades on one side of the shaft and the rotor on the other.  I was uncertain how well the plastic female receptacle would be over time from being subjected to the strong torque forces.  I decided to have the blades attach to the rotor itself.  The blades would turn the rotor and the shaft would only serve to keep the rotor centered.  This also allows me to add a disc braking mechanism on the other side as the electrical brake I contemplated will not be sufficient to stop the windmill in strong winds.

I acquired the blades and steel hub from TLGWindpower.com.  The hub came with a 17mm dead center hole.  The screw end of the shaft is 12mm.  I dedided to learn how to use a metal lathe and got one from Sherline.com  The lathe is precise to 0.01mm.  I machined a bushing that just fits over the 12mm screw and just fits into the 17mm hole on the shaft.

With the means to perfectly center the steel hub on the rotor I precisely drilled holes into the rotor.  Each end of the hub would receive three holes to secure to the rotor for a total of 9 holes.

I modified the washers so they would conform to the shape of the rotor on the outside and inside.

Here you can see the complete rotor-hub assembly.  I've sprayed the steel hub and F&P rotor with rustoleum primer and then enamel.  I've coated the grade 8 steel fully threaded bolts with marine triple-guard grease to protect the metal from moisture which would cause rusting.

I ran a quick test by overdriving my 1.5hp motor.  Everything ran perfectly: I got 1300watts at 700rpm and the rotor moved smoothly.  When I turn the assembly by hand I notice the slightest cogging, and that is only because I am looking for it.