Exploring the Magic of Electricity Making A Motor Exploring the Magic of Electricity

TOOLS Flathead screwdriver Wire Strippers Diagonal Cutters Phillips Screwdriver Needle Nose Pliers

2’ 20 gauge enamel coated magnet wire Wire Materials 2’ 20 gauge enamel coated magnet wire 18 gauge bell wire 12 gauge solid copper

Motor Parts Alligator Clips 2 wood screws ¾” 1” cardboard tube Wood block 3”x3”x 3/4” 2 wood screws ¾” 1” cardboard tube magnet

Step 1: Making connecting wires Attach an alligator clip to one end of black bell wire. Repeat for 2nd black wire.

Attach an alligator clip to both ends of white bell wire.

Step 2: Forming the motor brushes Cut a 1’ piece of 12 gauge copper wire in half.

You should have two 6” copper wires…

Using needle nose pliers, form a small hoop at one end

Holding the hoop, bend a right angle 1” below hoop…

Form a second hoop off the right angle

Bend another right angle from second hoop. First hoop Second hoop

Repeat Step 2 for the other half of copper wire Repeat Step 2 for the other half of copper wire. You will have two brushes. First hoop

Using wood screws, mount the brushes 1-1/2” apart on the wood block, hoops facing out. First hoop Second hoop

The brushes should look like the picture below. First hoop First hoop Wire connection point Wire connection point

Step 3: Place a magnet in center of brushes.

Step 4: Making the Rotor Materials: 1” cardboard tube, enamel wire, sandpaper.

Using cardboard tube begin making a coil. Leave 2” of wire at ends. Using cardboard tube begin making a coil.

Keep coils neat. 5-6 turns should do.

Carefully move coil of form, pinching coils together.

Pinching one side of the coil, make a loop with a free end around the coil to secure it.

Like this! Make two loops to secure.

Repeat for the other end of coil to secure windings.

Place coil in middle of brushes, trim excess wire.

Repeat for other side.

Using sandpaper, sand away enamel all the away around one end of coil. Bare copper end

The complete rotor. Sand away enamel 1/2 the away around other end of coil. Remove half the enamel from this end! (semi-circle bare) Enamel removed all the way around this end.

Step 5: Inserting rotor in Brushes. Slide coil through brushes, use needle nose pliers to bend one brush to ease installation. Motor brush

A Completed Motor Assembly

Attach wires to brushes using alligator clips on connection points.

Making Simple Switch

Cut two pieces of black bell wire, equal lengths STEP 1: Cut two pieces of black bell wire, equal lengths

STEP 2: Strip wire ½”

STEP 3: Make a hook in wire

STEP 4: Fasten wire and strap metal to wood

STEP 5: Screw into place

STEP 6: Fasten bell wire at other end of switch block

STEP 7: Screw in place

Completed Simple Switch

Complete motor wiring using a simple switch and 6 volt lantern battery.