Not to raise alarm but looking at your picture of the rewound stator, there is enough varnish that the space between the poles is filled.
Harley Davidson used to attach the leads between the poles and fill the space with epoxy. I have seen 100's of Harley stators where the poles with the epoxy failed, from the extra insulation of the epoxy. The newest versions use a different lead attachment system.
The purpose of the varnish or resin dip is to keep the wires from vibrating and failing. A thin coat does this just as well as a thick one. Where an alternator is exposed to water with road salt, like on cars, the thick dip is often better, Enclosed in a crankcase, water should not be an issue and I personally would prefer a thin Dip
Now this is NOT a HD, so maybe it does not apply, It will be an interesting experiment.
And I only know about HD
Your stator may be fine, the wire used might be higher temp than BMW used, and the thick varnish may not be an issue. But if it fails again, opt for thinner varnish coat.
ragtoplvr screwed with this post 07-14-2011 at 09:26 AM