I went the route
of putting a bridge rectifier in my air x. It lasted the longest it had in one stretch which I think was around 3 years. Then one windy trip down the coast (gusts in excess of 50kts) the stator overheated and fried. Southwest windpower wanted $185 and I wasnt taking. Instead while toying with ideas I noticed the similarity in sizes between the airx case and a 10si chevy alternator
. I ended up having aluminum
tabs welded to the windgen case and making a custom unit. On ebay I purchased a slant core
7 rare earth magnet , modified 10si alternator
. I got the alternator delivered for around $150 I then purchased 3 raptor IV blades with hub for $80. They claim good to 140mph winds. the bearing in the case was found for $6 as a replacement atv axle bearing. I had to reshape the tail and make it larger to account for moving the blades forward some and increasing the size. To seal the unit up I made a fiberglass
cover that goes over the front assembly and has double rubber seal on front. The whole shaft is packed with grease under the spacer outside. I just hooked up an ammeter and havent seen the high wind output. At 10-15 was putting out around 5 amps. Why did i go through all this? I was told the armature is a long term investment and wouldnt need replacement soon, stators are available rewound for wind gen purposes for $35.The other failure prone part rectifier is aound $12 I can carry a spare or two at that price
.Alternator claims output of 1500 watts max, Ill never see close to that so maybe it will last.