So I may have found someone to do the lathe work i require. If it pans out then I will be making progress very soon. I have been watching farfle's motor rewind and noticed him doing all the strands perpendicular to the stator tooth, and he has a tool filling the other half of the slot vertically. I had been thinking how to wind mine on the diagonal like the factory version, but now i would love to know which gives you less end turn loss; would seen to me to be farfle's since horizontal is less distance across the end then diagonal would be.
I am also now thinking that since I will have to manufacture an axle anyway I may as well go whole hog with proper wire space by widening the bearing whole in the cover plate slightly, getting a high strength needle bearing (i assume i will be able to find one within strength tolerance and i think that's the thinnest style bearing? i may be wrong), and then lathing out a ring that fits between bearing and axle that will have holes for the phase wires and hall sensors, a set screw to hold it tight to a flat ground to the axle, maybe a keyway, wouldn't want that part suddenly spinning with the covers if the bearing seized... if I could make it wide enough for computer cooling fittings I could run a simple water cooling system