Alright you want to make a badass motor? Then listen up...
Step 1. Go to the hobby store
Step 2. Ask them for a 5HP DC brushless motor
Step 3. Give them the money which you made by working hard at that IT job.
Step 4. Using the ideology that money is just an exchange of labor take credit for building such an awesome motor.
Now if you want to make the motor shown above then get the following materials:
Item 1: Transformer winding wire.
Item 2: 12x 0.5"x1/16" rare earth magnets (you may have to beg China by the time you are reading this)
Item 3: 2x 0.625"OD and 0.25"ID bearings, I tried inserting 1.75mm steel wire into my replicator 2 to print my own bearings but things didn't go so well and now Makerbot wont return my calls.
Item 4: Patients... I hope you have a Lord of the Rings marathon coming up because you're going to be winding this motor for a little bit.
DO NOT PRINT: the magnet.stl and bearing.stl
These are just to help you find the parts/get an idea.
2x shaft.stl - May want to print these with a higher infill %
First wind the stator, so how do you wind the stator? Well i'm glad you asked:
Step 1: Go to the hobby store... wait... no... Get yourself some masking tape and a Sharpe (not the dog). Choose your favorite stator "arm" that you want to wind first and using a marker and the tape mark that one "A - CW"
Step 2: Now the stator arm straight across from the one you just marked, mark that one "A-CC".
Step 3: Choose an adjacent stator arm to the "A-CW" one and mark that one "B-CC"
Step 4: Now the stator arm straight across from the one you just marked, mark that one "B-CW"
Step 5: Alright two stators left... I bet you can guess what to do next because... hell you're a maker... and a damn smart one too. But just to make sure "your friend" (wink wink) does it right I'll tell you. Choose the unmarked stator arm next to "B-CC" (should only be one) and mark that "C-CW"
Step 6: Only one stator arm left... mark it "C-CC"
Now what the hell was all that marking for? Well A/B/C are your phases and CW represents "Clockwise" and "CC" represents "Counter-Clockwise". So when facing the stator "arm" straight on that's the direction you're going to wind the wire.
On each stator arm I did about ~300 turns, remember the more turns the less educational and more badass this motor becomes.
When winding each phase (A/B/C) you want the wire to be continuous from the clockwise arm to the counter clockwise arm hence all the little pegs to run the wire around in. See my crappy drawing or "schematic" above.
Now that each phase is wound (English is nuts wind transformers in the wind, while your friend wound transformers with a wound) solder "A-CC", "B-CW", and "C-CC" together so it resembles the schematic.
Now pop the bearings into the _top.stl and _bottom.stl parts your printed... they should fit pretty tight, may need an exacto blade to get it just right.
Taking your 12x magnets, place them into the rotor like shown in the image above so you have one side "North" and one side "South". Take the two "shaft" parts and slide them into the rotor, one side should sit flat while the other sticks out just a bit (0.025"). The part that sticks out should point towards the stator nubs.
Slap the whole thing together, get some manly N-Channel and P-Channel MOSFETS, an Arduino for the blog cred (credit: xkcd), and get that baby commutating. I'd suggest looking online for how to put together a 3phase H-| (terrible joke) bridge to drive the motor.
To commutate the motor through its six states you want to apply V+ to the first letter and GND to the second letter. For example:
AB - Means A is at V+ and B is at ground.
Here are the six commutation states
AB, AC, BC, BA, CA, CB (and repeat)
Faster you go through those six states faster the motor will spin... but remember to ease into the faster speeds or your rotor wont be able to keep up and all your friends will laugh at you.
Oh and the mounting holes on the end caps are meant to be 4-40 tapped.