I made a mold for the
magnet rotors out of 20mm mdf.
I use my router and went around the outside of
the 10" steel disc
with a profile
cutting bit which gave
me a 10.5" hole.
used a 5"
hole saw and cut out a bit of wood for
the middle part and I
gave it all some paint so it would come out of the mold.
I glued the magnets onto the 10'' steel
disc with glue just to hold them in place
ready to put it into the mold. I had difficulty trying to
stop them sticking
together when placing them on the metal disc and
squashed my fingers a couple of times.
I put the magnet rotor in the mold and centered it
up, then poured the resin into the mold.
The only slimy thing
find as a releasing agent was baby nappy
worked and the rotor disc came out of the mold easily but it was messy!
When the resin was setting it gave
the magnets a
nice orange glow.
I put a piece of sand paper on a piece of board and set
the turbine to sand any high points of the magnet rotor.
I finally welded the tail hinge onto the main body at 45