Fuelless Engine 50 HP-Free Energy
Fuelless Engine 50 HP-Free Energy
Fuelless Engine 50 HP-Free Energy
#362
SCIENCE PART ONE
es
ellles
The Fuell esss
ENGINE PART 1
E
C Copyright 2005
ENC
Thank you for buying these plans, we hope you I Copyright 2005 Creative Science
SC
enjoy them. E
TIV
A
The Fuelless Engine is our trade mark and is a spin C RE
off of Nikola Tesla technology as well as our own.
This motor is like no other electric motor in the world.
You can run this motor on 300 to 2,000 volts dc,
(using a special coil design as well as the designs
included in these plans, see our high HP plans as well,
they have even more info that you may need. )
Many people do not know this but an Engine can also be Our RC Nano Flux High Hp Fuelless Engine #362-RC
called a motor and an electric motor can also be called an For High Voltage Power Supply see page 32
engine. These terms have been debated since the early
1900’s and to this date.
COVER
#362 PART ONE
+
PO BOX 557 New Albany, IN. 47151 USA
Knowledge is Power!
Introduction
What is Free Energy?
There are many examples of free energy, one example is the sun. The
sun gives off free energy and we collect that energy in the form of heat
and electricity everyday. We use solar cell technology to collect the
suns electrical energy and turn it into usable electricity. But is the sun
perpetual? No, but some people when they think of free energy they
tend to think of perpetual motion, but they are not always the same.
When the DC electric motor was invented it was found that it gave off Free Energy
free energy in the form of back emf. This new type of free energy Solar Panel
reversed the incoming polarity of the motors copper coils ( incoming dc
pulses ), causing the soft iron cores ( electro magnets ) of the top of
the motor coils to change poles, from north to south. This changing of Diodes
polarity and poles caused by the free energy from the back emf,
caused the motors to work against themselves and this is still going on
in many DC motors that are manufactured to this day. So now we see
that all common DC electric motors used today produce free energy in
the from of back emf and is not being used or designed in a way to +
take full advantage of this free energy output in which earlier design
engineers seen as a disadvantage rather than a high efficiency DC Motor
solution.
Primary Secondary
+ +
SW Electrolytic Transformer
12 vdc battery Capacitor
Diode +
one way DC Volt Meter
Introduction 1
#362 PART ONE
+
PO BOX 557 New Albany, IN. 47151 USA
Now after 3 seconds turn off the 24 vdc power, the positive flow
of electrons will now reverse because the electromagnet was
turned off. this is similar as the effects of a permanent magnet
generator.. When the magnet passes into the coil area and to it’s
center a voltage is produced in the wire, when the magnet is
then moved out from the center of the coil and leaves the coil
area this reverses the polarity and produces another flow of
electrical energy ( back emf ) the same amount of energy as
before. You will notice the volt meter needle move when you
turn off the power. This is free energy from a collapsing
magnetic field. Capacitors also store and collect free energy
between it’s plates in the form of r...? energy. Electrons are then
stored and collected on the metal plates. RPM Meter ( laser type )
You can buy at
http://www.allelectronics.com
An example of a
HV Electrolytic
Capacitor, good for HV power supplies. Introduction 2
#362 PART ONE
+
PO BOX 557 New Albany, IN. 47151 USA
There are 2 types of Capacitors, The dry type and the wet type.
An electrolytic capacitor is a wet type and is good for many things
such as HV step up power supplies. Electrolytic Photo caps are
the best, they are very high efficient. An electrolytic type capacitor
will always have a + plus side and a negative side marked on them.
A dry type or AC oil filled type capacitor is not electrolytic, AC or DC
can be applied to them. You can place the + positive charge lead A HV Electrolytic Capacitor
on either side of the capacitor and it will not harm the capacitor. 450 vdc x 350 uf
Figure 2
- 24 vdc or higher HV Oil filled Capacitors
- Electrons stored here
( For line poles etc..)
1/16” air space R....energy stored here......
+
PO BOX 557 New Albany, IN. 47151 USA
Spiral Coil
Photo 1 of small test model of a Fuelless Engine
or you can also call it a motor as well as an engine.
+ 300 vdc input pulses at about .05 milliamps.
Introduction 4
#362 PART ONE
+
PO BOX 557 New Albany, IN. 47151 USA
Figure 3
+ 1000 feet #25 AWG wire
1000 feet
No air space
1000 + 1000 = 2000 ft total
A common DC motor vs our Fuelless Engine: A common DC motor is designed to be an amperage hog! ..
It uses large gauge wire ( fat wire ) with very few turns for it’s motor coils. The coils are then of a low resistance. Doing it
this way is a waste of energy and money! The windings are also hand wound on most of these motors and are not
perfectly wound side by side as they are in transformers. By using more copper wire or more winds and using smaller
gauge wire ( thinner wire ) the efficiency of the motor goes way up. Also notice figure 4, the copper wire is wound around
a movable rotor of soft iron, this is not an efficient way of doing it. It is best to allow the magnet to move inside of the
copper coil. As we do with our Fuelless Engine motor. This creates a powerful generator and motor. As the DC input
voltage is passing through the coils to turn the motor the motor’s rotor magnet acts as a generator causing the flight
patterns of the electron /atoms to collide creating more energy! This is why you can see more energy output than input.
For example: we can input 1200 vdc into our motor coils and get a demonstration of about 10,000 volts back out at the
commutator brushes in the form of arcs, sparks and plasma balls. If we ever learn how to harness that energy the motor
will produce an even larger display of high efficiency! The more winds of copper coated wire, the higher the efficiency!
+
PO BOX 557 New Albany, IN. 47151 USA
N
S
strong south magnetic pole is created
within the spiral coils which in turn pulls S
the north pole of the rotor magnet AIR
downward toward the coils, and at the CORE
+
PO BOX 557 New Albany, IN. 47151 USA
Fig 1 ON 1:00
To HV DC
Power Supply
ON
Copper or brass
springs
To Coil Commutator
N
Black tape
Thick
Commutator SW
Black Tape
Copper pipe Brushs Qty 2 2nd not seen
it is behind the 1st one.
FRONT VIEW
Copper pipe = buss bar
Thick insulation must be used, such as thick We pulse the negative of the HV DC
black tape or the back emf sparks will be so
great it will destroy any thin insulation used. Fig 2 OFF 1:00
The back emf voltage output is far greater
than the front emf voltage input! S
For the buss bar:
We use copper pipe, Copper pipe is great for
OFF
using as a buss bar for the commutator. We
then use black tape for insulation as seen in
Figure 1 & 2. The copper pipe commutator
is connected to the rotor shaft. You can also Commutator
use PVC pipe and glue and wrap copper foil Thick
around the pipe, you can use 3M spray Black Tape
adhesive to keep the copper foil in place.
Copper foil tape could also be used.
See internet for suppliers. N SIDE VIEW
E
E NC
For High Voltage PowerCI
Supply see page 32S 6:00
E
TIV
A
C RE Introduction 7
#362 PART ONE
+
PO BOX 557 New Albany, IN. 47151 USA
WARNING! We are not responsible for anything in these plans, you build at your own risk! The
motor can run on high voltages by very low milliamps, but the power supply carries high voltage by
3 amps. if you make skin contact with the power supply death or injury could result! High Voltage
can kill! always wear rubber gloves, rubber shoes, rubber or plastic lab coat as well as eye protec-
tion. Label all high voltage parts and work area with High Voltage warning signs! Once your motor
is complete encase the motor in some kind of safe motor housing. Encase all electrical parts. Since
you are building a high voltage motor do a professional job! Do not be sloppy! WARNING! #2
Our motors can give off strong (RF) Radio frequencies if commutator spark is not controlled! The
larger the spark the more RF output. Keep all sensitive electronic equipment at least 20 feet or
more away from motor while running. ( If RF sparking occurs at brush commutator area ). Do not
use Digital voltage meters, use analog type,( needle type ). Electronic equipment might be
protected if you place them in thick steel boxes. While running tests.
N38 Neodymium
Magnets
All Aluminum
Structure
Page 1
#362 PART ONE
+
PO BOX 557 New Albany, IN. 47151 USA
WARNING!
You can not copy or duplicate any part of these plans in any
shape or form without the written permission from Creative
Science & Research. You can not resell copy or give away
these plans in any part. that includes photo’s etc.. As well as
our videos. Round type
Copyright 2005 Creative Science & Research Copyright 2005 Creative Science & Research
r
c Powe
1200 vd ply
Sup
E
E NC
I
SC
E
TIV
A
RE
Small hp motor Our Large hp motor
C
Creative Science & Research
Spiral Coil Technology
Page 2
#362 PART ONE
+
PO BOX 557 New Albany, IN. 47151 USA
Our Fuelless Engine technology is basically, high efficiency, free energy, electric generator and motor
technology, and uses new technology developed by David Waggoner and Rick H. of Creative Science &
Research. Our small spiral coil pancake motor is very high efficient. The rotor has 1 7/16” Diameter N38
Neodymium magnets connected to it’s shaft. HV DC current is applied to the motor coil and spins the rotor
very quickly. The commutator brush assembly acts as a switch to turn on the HV DC current at the proper
time, so the magnets will spin correctly. This engine / motor is also based on Nikola Tesla Technology. Free
Energy has been suppressed since the early 1900’s and is still being suppressed to this date. No one can
manufacture or sell any free energy device at any time! If you do decide to build this motor you must keep it
to yourself under lock and key! Take your time, study the plans well and take it one step at a time. Our
Video shows the motor running as well as many other features. If you build this motor right it will run on
small milliamp currents and demonstrate high rpms and hp. We have had a lot fun with this motor and I
know you will to. Free Energy is being produced in the form of back emf and is being reused by the motor
coil and by it’s capacitance, causing this motors efficiency to sky rocket!
This motor can run only on milliamp currents. Back emf is free energy created from a collapsing
magnetic field generated in a coil of copper coated wire wrapped around a soft iron core or air core.
Back emf can also be stored in batteries or large capacitors to be reused.
By using thousands of winds of copper coated wire in our coils we have been able to increase the
capacitance and efficiency of the motor, causing the motor to run on very little amperage. ( When the
commutator is controlled ). If we input 360 vdc in to this coil, the motor will clearly demonstrate an
output of about 3,600 vdc at the brush commutator SW. For research purposes we use 120 vac and
then step it up using our dc HV multiplier ( Diodes and Capacitors, see #378 plans for only $9.95 ) The
voltage is stepped up to 360 vdc. This motor can also be ran by using a 12 volt dc battery, 115 ac x
75 watt inverter, passed through our #378 HV dc multiplier. Most all free energy devices must have a
small input of energy to get the free energy reaction started!
Page 3
#362 PART ONE
+
PO BOX 557 New Albany, IN. 47151 USA
+
PO BOX 557 New Albany, IN. 47151 USA
Back Page 5
Use Nylon nuts and bolts to connect the brushes and PVC plastic
Part # 9b insulators to Part # 9a
#362 PART ONE
+
PO BOX 557 New Albany, IN. 47151 USA
Page 6
#362 PART ONE
+
PO BOX 557 New Albany, IN. 47151 USA
www.lucasindustrial.com/products/shaft_collars_couplings/solid_collars/
+
PO BOX 557 New Albany, IN. 47151 USA
Thank you
David Waggoner
sales@fuellesspower.com
Page 8
#362 PART ONE
+
PO BOX 557 New Albany, IN. 47151 USA
N
+
+
6- 32 x 1/4”
Machine
Screws
N CE Drill hole
C IE slightly
S
E smaller
ATIV than the
C RE head of
the screw
so the
motor
Make about 19 layers of
#27 AWG spiral coils + mount can
be adjusted.
Or you can
make as a
tight fit.
Part # 5
Motor Mount
Aluminum
Donut 1
6 2 Inch OD
Disk 3
7 8 Inch OD Part # 5a ( hidden
under Part #5 )
Aluminum Donut Tap out
Spacer. Use 2 way (thread for
carpet tape to short bolts )
drill bit 3-7/64”
5 attach to top coil tap = 6-32
3 8 Inch ID array.
If this spacer is not 5
thick enough, use
3 8 Inch ID
thin washers to
Page 9
#362 PART ONE
+
PO BOX 557 New Albany, IN. 47151 USA
Part # 18
Part # 12a
Pa
rt #
19
Par
t#9
a
N
Part #
9
Part # 2
PVC pipe
+ Part #
9
+ Pa
rt #1 9
9 Part #
rt # 9
Pa
6 6- 32 x 1/4”
rt #1 Machine
Pa Screws
Part # 5
Aluminum
Donut
Copper pipe
Part # 5
Homemade copper + N CE
pipe commutator. IE
Entire assembly = SC
E
Part # Cm26 Spiral coil Array ATIV
glued to 1/4” PVC Copper foil RE
sheeting ( Disk ) input leads C
entire assembly =
Part # Sa27
You will begin making the Spiral coil array first, this maybe the hardest to do, but will be well worth the
effort. You will first wind each spiral coil layer at a time. Each layer is connected in series or you can wind
the bobbin in a conventional electromagnet way, much like the windings of the primary coil of a transformer,
right to left method side by side. This method is less efficient than spiral but will work. You will then be
using 3M spray adhesive to get the wire to stick to your base while you are winding the wire side by side
and turning the base. The wire does not need to be cut when you get to the end of the wind, but is wound
back through the paper spacer(s) ( which should be the same thickness as the wire )and back through the
slit in the center of the coil or PVC pipe. You will be winding one layer at a time from a continuous wire roll
or 6 lb spool of #27 AWG copper coated wire. Once you have about 19 to 20 layers then solder the copper
foil input leads to the 2 input coil wires. At this point you have 2 options; 1. You can leave the spiral coil
array just the way it is or 2. completely coat it with 2 part clear epoxy to protect the coil array from damage
( Recommended ) You can do this by making a wooden mold from plywood or other, to loosely fit the coil
array inside of the wood mold, allow about a 1/8” space on top and a 1/4” space on sides and bottom. You
can use small finishing nails, nailed through the bottom of wood mold at about 1/4” length through the back
of the wood. Then lay the array on top of the nails. Again, you will want the epoxy about 1/8” thick on top
and about 1/4” thick on the sides and the bottom. DO NOT ALLOW BRUSHES ( part #12a ) to hit any part
of the rotor shaft ( Part # 16 ) while running, motor will short out and run slow.
Page 10
#362 PART ONE
+
PO BOX 557 New Albany, IN. 47151 USA
Page 11
#362 PART ONE
+
PO BOX 557 New Albany, IN. 47151 USA
Rotor Shaft
N
C E
EN
Use #27 copper High Voltage
coated wire, double
DC Input I
coated = about 4 lbs
SC
or 290 ohms
+ IV E
T
EA
CR
The above drawing is an example of just one motor coil. When a DC voltage is applied a strong magnetic
flux is created in the center space of the coil creating a strong electromagnet. The coil is very high
efficient! You can create a north pole or south pole magnetic flux in the center of the coil by using the
positive on one side or the other. Only the top part of the coil is used in this drawing, the bottom is not used and is wasted.
The bottom side of the coil can be used as another motor source or transformer generator type device while the motor is running.
Making a spiral coil can be some what time consuming, but it will be well worth it in the end. The above
drawing ( Figure #1 ) is just an example of a small hp spiral coil motor. It is best to use a spiral coil and is
the most efficient way to build this motor. But you do not have to use a spiral coil, you can use the left to
right winding method, each wind should be side by side, starting from the left and then going to the right
and then back to the left, No spaces and no overlapping other than overlapping for each layer. Each layer
should be covered with very thin rigid cardboard or plastic or you could use 2 part 5 min epoxy on each
layer. Another option is to use square wire, it would lay side by side much better than round wire, but
maybe more expensive.
Again the coil will also be acting as a large high voltage capacitor and if you have ever built a capacitor
you know that the plates must be of the same size and have equal amounts of spacing or die electric
spacing. So the more capacitance in the coil the more free energy. The motor will reuse this energy to
help run itself, causing the motor to be very high efficient. If you wind the coils any old way having spaces
and many over laps of wire the motor will work but will be less efficient. Winding the coils should be a
very slow process it will take a long time but will be well worth it! Transformer coil companies have
machines that can turn the wire side by side perfectly, but those machines cost thousands of dollars. You
could contact a transflormer and or coil manufacture and they would wind the coils for you. Or you might
try a motor repair shop in your area they may have a machine to do it as well. If you are good at
designing and building, you could make your own automatic coil winder using long bolts ( Fine thread )
as a mover nut assembly. The nut and the wire guide will ride the long bolt. To turn the mover wire nut
guide you will need a 90 vdc conveyer belt motor with a speed controller from grainger.com it would cost
about $125. You will also want to add a switch to reverse the polarity of the motor so it will reverse and
bring the guide back the other way. You could use magnetic replay switches at both ends of the bobbin,
and of course you would want to make them adjustable. You could try converting a small lathe. The higher
the resistance the less amperage the motor will need to run on and the higher the efficiency! ( the more winds the better )
Page 12
#362 PART ONE
Fig 2
Fig 3 Drill Press
If you carefully study the motor coil and rotor magnet design you will see that it is very
different from any other motor that is manufactured today! This is not just a motor but a
motor generator that produces free energy to help run itself! Most all generators and
motors today use copper coated wire wrapped around a soft iron core. And the iron core
does not move. If the same control method is used it should be possible to increase hp by
using soft iron cores for both stator and rotor. You can make your own soft iron cores by
using soft iron power ( as round as you can get ) and mixing the iron power with 2 part
epoxy and making a wooden mold to make your own molded iron cores. This is the best
way to make a homemade iron core and is the most efficient. There are companies that will
make the molded iron core for you to any size you wish. ( Search the internet ) The iron
cores should be made strong. Most companies mix the epoxy and soft iron powder together
and pour it into the mold, then they compress the mixture with about 400 to 600 lbs of
pressure to squeeze out the access epoxy and air bubbles. It is then allowed to dry and is
heated. By making soft iron cores this way there is no need to use laminated iron cores,
which is widely used in most motors and transformers today. Once you learn the technique,
you can build soft iron molded cores to any size or shape that you want. When the molded
cores are magnetized, each nano size ( round is best ) piece of soft iron within the molded
iron core, acts like a magnet! And since the molded core has thousands of these tiny
magnets stacked side by side the iron core can become a high efficient super electro- EXAMPLE OF A
MOLDED IRON
magnet when energized by the high voltage flowing through the copper coil. CORE
ed. The 90 vdc motor controller uses 120 Epoxy coating around each nano powder of iron
vac and then steps it down to 90 vdc to run so the nano pieces do not short each other out.
the motor. Option 2 is to build a large round
wooden table with a Lazy Susan connected to the bottom. The PVC bobbin can be taped
with 2 way carpet tape to the top of the wooden Lazy Susan or held down with wood screws
or nuts and bolts. you will need to turn the entire structure by hand. Which is a very slow
process.
Page 13
#362 PART ONE
N CE
C IE 1/4” or 1/8” PVC bobbin
S
E
ATIV
E
CR
ASSEMBLY: Your PVC Bobbin should now be done and been allowed to dry for about 24
hrs. Attache the ½” long bolt connected to the PVC bobbin to your drill press chuck and
tighten. Unplug your drill press. Place a paper protector around the PVC center pipe ( part #2
) paper should fit tightly and flush on the bottom with the PVC disk. Now spray the top of the
PVC disk with 3M adhesive spray, let it dry for about 2 to 3 minutes. Open the top lid of the
drill press. Place your 5 to 6 pound spool of #27 Copper coated wire upright on the floor in
between your legs were you will be sitting in front of your drill press the wire will come off
from the top very easily.
Now it’s time to begin turning the wire onto the PVC Bobbin. Place the beginning of the wire
in the start hole area B. allow about 12” to come through the hole and tape it to the bottom of
the PVC bobbin using masking tape. Now you will want to start spinning the large pulley on
the drill press by hand to get things started. Don’t rush, but take it slowly and at the same
time guiding the #27 wire side by side around the PVC pipe part #2. Try to keep your first
wind as close to the PVC pipe as you can. ( no spaces and no over lapping ). Try using the
end of a razor blade ( the end that is not sharp, see photo ) use this to guide, press down and
push the wire into position so it will also stick well to the spray adhesive. Be careful not to
scratch the coating off the wire, if you do then paint the exposed area with enamel paint or
other and let it dry before going on. You may have to re-spray with adhesive. Make sure you
have good ventilation, use a fan if you have to and a mask. Once you have about 1.5” wide
of wire wound around the PVC pipe and flat to the PVC disk surface, you can plug in your
drill press, ( Drill press must be converted to a low rpm adjustable speed drill press by using
a 90 VDC conveyer motor and speed controller ) and turn on your speed controller at it’s
lowest speed, keep one hand on the speed control and one hand guiding the wire onto the
disk. If you mess up you can Quickly shut off the motor. Don’t worry it’s not that hard, you will
get good at this the more you do it. When you become better at it, then you can speed up the
motor a bit more. Wind the wire all the way to the end of the disk, Stop the motor... You have
now completed one spiral coil layer.
Now mix 2 part epoxy and spread it thin and even onto the top of the wire. Make sure you
cover the entire area of wire. If epoxy is still sticky and not dry you can place your Part #6
paper separator over top of it and smooth it down flat and place a 8” donut plywood board or
steel weight over top of that and let it dry for 35 to 40 minutes. If 2-part epoxy has already
dried, then re-spray the top of the wire with 3M spray adhesive. Now take part #6 ( the
paper die electric separator, cut as shown on page 5. ) Spray one side of the paper with the
3M spray adhesive and spray the top of wire again with a thin coat of spray adhesive, let dry
for 2 to 3 minutes then place the Part # 6 Paper over top of the copper wire spiral coil that you
completed. Press down firmly getting out as many air bubbles as you can. * Now spray the
Top of paper with a thick coat of 3M spray adhesive. Take the wire straight through the paper
slit and through the left slit in the PVC pipe ( part #2 ), then the wire should be inside of the
PVC pipe you then direct the wire back through the 2nd right slit in the PVC pipe and start
winding your 2nd spiral coil layer on top of the first layer. Repeating the same steps as you
did before. Continue, keeping to these steps until you have about 19 to 25 layers. The more
layers the better! See photo’s on next page, page 15 they maybe helpful.
Page 15
#362 PART ONE
The Fuelless Engine
Copyright 2002 - 2005 Creative Science & Research
Page 16
#362 PART ONE
The Fuelless Engine
Copyright 2002 - 2005 Creative Science & Research
# 27 AWG Wire
Page 17
#362 PART ONE
The Fuelless Engine
Copyright 2002 - 2005 Creative Science & Research
Page 18
#362 PART ONE
The Fuelless Engine
Copyright 2002 - 2005 Creative Science & Research
TOP VIEW
C E
IEN
SC
VE
TI
E A
Step Four CRStep Five Step Six
No spaces
For illustration
purposes only
Now that you have successfully completed your motor coil Using a volt meter with ohms and capacitance
capabilities take an ohms resistance reading and write the results on top of the paper of the coil, next take a
capacitance reading and do the same. You will now need to weigh the entire coil and write that down as
well.
Page 19
#362 PART ONE
The Fuelless Engine
Copyright 2002 - 2005 Creative Science & Research
Side View of Spiral Coil Array. Paper can over lap 1/4” or less or can be even with copper ends.
1/4’ PVC
PVC pipe
Page 20
#362 PART ONE
+
PO BOX 557 New Albany, IN. 47151 USA
1
Part # 5a 6 2 Inch OD Once the spiral coil array is built and is coated
with 2 part epoxy for protection, You will then be
attaching part #5a to the top of the spiral coil
array using 2 way carpet tape. If part # 5a
Tap out needs to ever be removed you can do so by
(thread for
short bolts ) soaking the carpet tape with mineral spirits or
drill bit 3-7/64” paint thinner. At this point you should have 4
tap = 6-32 holes on the top of part # 5a that are tapped out
( threaded ) Part # 5 will then be fitted with the
5 entire motor assembly when completed and
3 8 Inch ID
connected to the coil assembly and bolted into
place using short bolts. ( Lock washers and
Option 2: Motor mount spacer can also be cut to same size steel washers should be used as well ).
as Part #5 if you like. Cut to 7 3/8” OD if desired.
6 32 tap IE
C
NT
S “
E R
ER
C RE
ATIV
5 “ CENTE
8
1 3/8” 5
8
½”
Ho “ C
le
1
16
2”
½”
Page 21
#362 PART ONE
Now glue the air spaces in between the magnets with 2 part epoxy then let it dry overnight. You can
block the ends off with masking tape so epoxy will not drip out. Always keep in mind the rotor must
be as well balanced as you can make it. The rotor will be turning at very high rpms, if it is off
balanced the entire motor will vibrate and can vibrate parts loose. Use tape as wall molding to
keep the 2 part epoxy in. Make sure there are no holes in tape or the epoxy will leak out. Once
you have finished the north pole side use masking tape and card board to protect it from damage
or other magnets coming in contact with it when you start the south pole side. Use lacquer
Thinner or xylene to clean parts before applying epoxy.
Page 22
#362 PART ONE
Lay wax paper flat on a table top. Then lay the 5/16” x 14” round rod rotor shaft on top of the wax paper.
Tape the rotor shaft to the table top using strong heavy duty tape on both ends so it will not move. Cut
qty -2 5/16” round rod spacers as shown. Sand and clean with mineral spirits or other paint thinner, let
dry then mix and apply ( longer drying ) 2-part clear epoxy onto the middle of the shaft area, apply epoxy
also to the 2 5/16” spacers, cover them in it. Then place the 2 5/16” round rod spacers into place as
shown. Then tape to long 14” pieces of 5/16” round rod Top View
on both sides of spacers to keep them in place. Then
place a heavy flat object on top of the rod and spacers
and let dry overnight. Optional : Once this is dry you can
then drill 2 small precision holes through both the
spacers and the center round rod for steel pins to fit in.
Apply epoxy to pins before placing them in holes.
Mark 2 - N38 magnets with center marks. Now carefully place your magnets in the center of rod over top
of 5/16” spacers. Place the first one then the 2nd one, north on one side, south on the other. Get them as
well balanced as you can on the rotor shaft. Now tape open ends and all epoxy fill all spaces, cover the
magnets also. With a thin layer of epoxy. You may need to go back later and apply a 2nd or 3rd coat.
Page 23
#362 PART ONE
Contact Brush’s
STEP FOUR
Cut a small piece of 5/16” round rod to 2 inches long.
1 ½”
Page 24
#362 PART ONE
STEP FIVE
Sand 5/16” round rod with fine sand paper 5/16” Round Rod
PVC Washer C
then clean the round rod and inside of
pipe with lacquer thinner. Let dry, then C
Apply Grease
place copper pipe upright on wax paper.
Now apply white axle grease to the Fill with 2 part A
surfaces of A , B , and round rod. Do not JB Epoxy
allow white grease to come in contact
E
with the inside of the copper pipe. Now E
Apply
place washer D flat on the bottom inside Grease
of pipe. Mix 2 part JB weld Epoxy very B
well and fill E area ( inside of copper D
pipe ) to the line of A . Now place C PVC Washer D
washer down into pipe and push firmly to
squeeze out all air bubbles. Allow to dry
overnight. TOP VIEW
STEP SIX
Remove washer and round rod carefully,
turn round rod slowly and pull out. Cut
small shallow cuts with Xacto knife in
bottom B it will be the flattest area.
STEP EIGHT
Again timing the motor is easy. When the Copper pipe commutator is fully assembled simply turn your
magnet N to the 1:00 position and mark were the end of brush is in contact with copper pipe. Then turn to
the 6:00 position and again mark were the end of the brush’s are in contact with the copper pipe. Now using
your marks as a guide apply insulation black tape from the 12:15 position counter clockwise to the 6:00
position. See Introduction page 7 or fig 4 above. ( You may need to adjust the length a bit? ) Trim all access
tape off with an Xacto knife or sharp razor blade. Once you have applied the black tape you will then need to
apply clear shipping tape over the black tape. The reason is that the black tape is a rubber and it is hard for
the brush’s to slide over. You want the least amount of resistance as you can get. Use double thick black
tape. If you do not use double thick tape the back emf voltage and amperage is so high that it will burn holes
right through your tape to the copper. The copper pipe, the tape and the brush’s also act as a HV Capacitor.
During motors operation the brush commutator area will clearly demonstrate more power output than input, in
the form of plasma arcs as well as large high voltage & amperage sparks and spikes which must be
controlled.
Page 25
#362 PART 2
Model 2
Model 3
#2
OPTIONAL
#1
CARBON
BRUSHES
Page 26
#362 PART 2
Part E
Part D
N
Part N #2
Parts Q #1
Part N
Large steel washer for
roller bearing cover.
Part A
8 3/8”
E
NC
C IE
S
E
ATIV
C RE
Part B
12”
PART “M”
3” BEND 3” BEND 2 ½”
Use a 8 ½” x 3/4” x 1/16” or best to use 1/8” steel bar. This is used to hold the Brush Assembly.
Page 27
#362 PART 2
SIDE VIEW
½” x ½” Steel or workable plastic ( PVC would work also )
#2
The number one and number 2 brushes must not short each other out. #1
They must not be electrically connected to each other only when the
copper buss bar makes contact with them. It is best to make the entire
assembly with PVC sheeting, not including the steel holder. If you use
metal material you will need to insulate #1 and #2 from each other. You
can do this by using epoxy glue in between the steel square and the
aluminum base ( Part “ G “ )
If using metal, make sure you apply 3 coats of spray enamel to all
metal surfaces, ( Not including carbon brushes ) Again the Commutator
assembly acts as an on and off switch and must be timed correctly so
the motor runs smooth and does not work against itself. As the copper
pipe buss bar ( # 3 ) rotates with the motors rotor shaft, the carbon
brushes hit the buss bar making a complete circuit.
1 ½”
Use a very fine hacksaw
blade to cut spacers, fill
spacers with epoxy and
2” 1 ½”
4 sand smooth.
Page 28
#362 PART 2
STEP THREE
Using a Q-Tip, Grease a piece of card board a little larger than the copper pipe
diameter, this is so the epoxy will not stick to the Card board surface and can be
removed when dry. You now need to fill the copper pipe with Epoxy, so slowly
squeeze out enough J-B Epoxy to fill the inside of the copper pipe, follow all
directions on the J-B Instructions, Mix the 2 parts very well and start placing the
epoxy inside of the copper pipe. Let dry 24 hrs, I prefer to wait 40 hrs, but the
instruction do not tell you that. We use J-B Epoxy because it is the best on the
market and can stand up to 600 degrees.
Figure #3
STEP FOUR
Now you must find the exact center of the pipe and Figure #4 Acts as a Junction Bar
score it with a sharp punch. You will be scoring or
punching a small hole into the top of the epoxy. You
Separates the brushes
will now need a drill press. Place the copper pipe up- from contacting each other.
ward as seen in figure #3. Make sure bottom surface Cut all the way around pipe.
is very flat, if it is not the hole will be crooked and the Make a double wide cut.
commutator will ride with the shaft crooked and cause 1 ½”
an off balance at high speeds. Start off with the
Use a hacksaw
smallest drill bit you have and work your way up until blade to cut spacers, double wide
you have a hole the same size as your shaft rods 1 1/4” cuts, fill spacers with epoxy and
outer diameter. sand smooth.
STEP FIVE Fill in the cuts with epoxy, let dry 24 hrs then sand
Now using a fine point marker, mark your cut marks down until smooth. Now take a 5/16” steel shaft
on the outside of the copper pipe piece. As shown in and place it back into the epoxy hole, now place a
figure #4. Use a fine tooth hacksaw to cut. steel 5/16” shaft collar onto the steel rod and epoxy
Cut a long center cut all the way around the copper it to the end of your new commutator,
pipe leaving a 3/4” space. Cut all the way through the ( remove the plastic end first. )
copper and just up to the hardened epoxy fill. Do not
cut to deep into the epoxy fill.
Page 29 of #32
#362 PART 2
” “F”
ART “F PA RT
½” P #1
#2
1 5/16”
½” + +
PART “F”
J - B weld or PC 7 EPOXY
Plastic Separator
RT “F”
PA 2”
1 1/4”
Brush: grease brush and place inside of square steel part # “F”, Let sit and
dry for 24 hrs, then remove brush and clean it off.
OPTION 3
Back side
As an alternative to using brushes, you could replace with heat
of motor
treated brass, copper or you could call it metal brass spring. Place
the copper on part “ M “ and bend the copper upward. You can
use wood or plastic as the base. It is very important to make a
good strong contact with copper pipe buss bar. + +
Page 30
#362 PART 2
12”
Aluminum 1/8”channel, Drill holes to 7/64”. You will need a qty of - 2. You will need to tap out each
hole, ( Thread it ) using a 6-3 NC tap plug style.
12”
1 7/8”
You will need three short pieces, two for the magnets to be used as spacers and one for a Shaft mold for making Commutator.
2 ½”
Use ½” aluminum bar. Check at: Machine shops, Steel suppliers in your Yellow Pages,
Steel salvage yards etc... Drill two holes on each arm, use a 5/16” drill bit. After you
install roller bearing assembly on part “ D “, remove roller bearing and drill a bigger hole
using a 11/32” drill bit. On Part “ E “ Drill only halfway through, so the 5/16 rotor shaft
Part “ D “
Part “ E “
Roller bearing assembly, Use a large steel washer, assemble this after you put
the Rotor shaft and arms together Once your shaft is running through Part “ D “
hole, you can then place the Roller bearing onto it. Grease the outer part of the
bearing, Predrill 2 or 3 holes in the large steel washer, place the large washer
over top of the roller bearing, center and mark your holes, use a 7/64” drill bit
and tape out your holes with a 6-3 NC tap, then attach the washer to Part “ D “
with 6-32 x1 ½” bolts. Now mix up some J-B weld or Pc7 Epoxy and fill the 4 1/4”
3 11/16” inside beneath the washer and all around the roller bearing. ( Make sure 3 11/16” connected in parallel,
bearing is greased well so you can remove it to later drill your larger hole.
The reason you need to dril l a larger hole later is so your rotor shaft can turn
½”
more easily. Let epoxy dry for 24 hrs, then remove your Steel washer roller
bearing plate, then remove your roller bearing, drill a bigger hole in Part “D” then
place you bearing back onto the molded roller bearing assembly.
2 ½”
Page 31
#362 PART ONE
can act as a HV capacitor and store energy which BATTERY BATTERY BATTERY BATTERY BATTERY BATTERY
N N N N
Electromagnetic South Pole Flux
More HP! Add more magnets, also use ½”round rod for a rotor shaft.
One coil set up, less HP
Model 4
Electromagnetic North Pole Flux
N
N N N N
S
Electromagnetic South Pole Flux
Fig 102
CUSTOM MADE N40 - NEODYMIUM MAGNET
Rotor Magnet
N
Magnet shaped
like this. Then all
N
S 8” S area.
Aircore type: we used #27 copper coated wire and constructed the bobbin
with 1/8” PVC sheeting purchased from a sign supply company. 3 strand
We then used N38 Neodymium magnets glued to a small steel rod used as the rotor shaft.
The magnet was place ½ way inside of the top of the bobbin coil and turned inside there of.
Page 35
#362 PART 2
Page 36
#362
The Fuelless Engine
Copyright 2002 - 2005 Creative Science & Research
Page 37
#362
Page 38
#362