Method of making an electric motor

A method of making an electric motor with a stator winding having coil end turns at axial ends thereof inside a slotless cylindrical stator shell of magnetic material comprising the steps of:

• forming a slotless cylindrical stator shell of magnetic material;
• creating a generally cylindrical support with a reduced diameter portion at one end;
• forming the winding around said support from preformed coils such that
• the coiled end turns at one end of the stator winding are at the reduced diameter portion of said support and flare inwardly along said reduced diameter portion, and
• the coil end turns at the other end of the stator winding are at the other end of said support and flair outwardly;
• inserting said winding into said cylindrical stator shell starting with said inwardly flared end coils while the winding is supported by said support;
• removing said support from said winding;
• and
• impregnating said winding with a resin to secure said winding inside said stator shell.