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

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

3. 2’ 20 gauge enamel coated magnet wire
Wire Materials
2’ 20 gauge enamel coated magnet wire
18 gauge bell wire
12 gauge solid copper

4. 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

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

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

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

8. You should have two 6” copper wires…

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

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

11. Form a second hoop off the right angle

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

13. 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

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

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

16. Step 3: Place a magnet in center of brushes.

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

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

19. Keep coils neat. 5-6 turns should do.

20. Carefully move coil of form, pinching coils together.

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

22. Like this! Make two loops to secure.

23. Repeat for the other end of coil to secure windings.

24. Place coil in middle of brushes, trim excess wire.

25. Repeat for other side.

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

27. 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.

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

29. A Completed Motor Assembly

30. Attach wires to brushes using alligator clips on connection points.

31. Making Simple Switch

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

33. STEP 2: Strip wire ½”

35. STEP 3: Make a hook in wire

37. STEP 4: Fasten wire and strap metal to wood

38. STEP 5: Screw into place

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

40. STEP 7: Screw in place

41. Completed Simple Switch

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