1951 Pontiac Chieftain

Took the gauges out again. Dismantled one coil from the armature.



Made a cammed section on the chuck of my drill with electrical tape and fixed it down to the bench. Then set up a small plate with a microswitch that's operated by the cam every rotation of the chuck.



Hooked that up to a small counter and unwound the wire from the coil.



All undone, cleaned up. The wire was all burned up along it's length and had fractured in 3 places.



Checked the diameter of the wire with my micrometer. That's 33AWG.



I've ordered a spool of 36AWG enameled copper wire. That has twice the resistance per foot, so the same number of turns on the bobbin will see double the resistance for 12V. I'll wind it and run it up to full power and see how hot it gets.

Phil

Treble bonus points for use of 'Ingenuity'

Doesnt quite work like that if your changing the voltage , its tricky to explain but its half the turns but double the wire size or the other way around depending on wether your going up or down re. the voltage , by double its not ( hypathetically speaking ) going from say 1mm to 2 mm , its done on wire cross sectional area , we have tables at work that calculate this .
No idea what 36AWG wire is as all winding wire is done in MMs or part thereof
If you need any help just ask away

Your correct in the more turns / smaller wire gauge. Heres a hypathetical example of how we do this at work
Multiply the original turns by 1.66 -
Example 380 turns x 1.66 = 631
Work out original wires cross sectional area and x by 0.66 , figure obtained is then cross referenced on chart to give new wire size.
Example 0.800 original wire size which has a cross sectional area of 0.502 , x this by 0.66 which = 0.33 cross sectional area , size nearest to 0.33 according to chart is 0.63.
So
6V was 380 turns of 0.800
12V is 631 turns of 0.63

200% has been tried before with good results , its very much a black art and nothing is certain . Sometimes the actual conversion doesnt give the result expected and sometimes an educated guess works just as well .

So you say your wire is 0.52 , the nearest i have on this is 0.53 ( thats quite thick ) Did you burn the coating off the wire before measuring it ??
518 turns x 1.66 = 860
Cross sectional area of 0.53 = 0.2206 x 0.66 = 0.145596
nearest wire with this cross sectional area is 0.4250 which doesnt exist anymore so we go the next size down which is 0.400

Going on how we would do it here .
Original 6V is 518 turns of 0.53
12V done as we do would be 860 turns of 0.400 .

I make your 0.0072 inch wire to be 0.18mm so just as an option


Original 6V 518 turns of 0.180
12V 860 turns of 0.140
Its also governed by how much wire will fit on the bobbin which often throws everything out the window anyway ,
This chart might help with the AWG


Heres a copy of the wire charts we use i found on the net , just the small stuff is relevant to you - bottom image but i put the larger ones in for the headings

No problem re. the help , only to glad to have a try if i can
Its a real minefield , i upgrade alternator stators to give higher output , one starts at 60A and ends up 200A , The amount of trial windings done is mindblowing , once its achieved though its easy the next time .
Keep us posted as how how it works out

That's a great deal better than it was before !

supreme levels of attention to detail

Very impressed i must say , coils will get warm for sure . Id test at 13.8V if you can as thats about what the running voltage will be . Enamel will take a lot of heat but wont take a short or overload which is what seems to have happened to your original one .
Well done , you can have a job at our place if you want .
Last thing i rewound for my car was this Denso stator . Trial winding to get more Amps on tickover which proved successful after two trials