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Any tried and tested way you guys have done this?

There used to be some 60 or 70 watt coils available, I think, and Baja Designs will rewind your stock stator to power their dual sport kit. I was able to power their dual sport kit by using LED bulbs in the directionals and tail light, and a Tusk "Blue" 35w bulb in the headlight. It all works fine on the stock stator (no battery).

Inda was working on dat awhile back

I rewound my stock stator with good results.

That is interesting, Nick. Can you tell us what was involved in that process - like, what gauge wire you used, how many wraps, and where you obtained it? I presume that the wire can be purchased at Radio Shack, but it has to be coated, correct?
I would like to be able to power a 55-60w headlight...

Check my build thread here or on thumpertalk. Can't remember off the top of my head but I believe it was 17-ga coated magnet wire.

gregp wrote:That is interesting, Nick. Can you tell us what was involved in that process - like, what gauge wire you used, how many wraps, and where you obtained it? I presume that the wire can be purchased at Radio Shack, but it has to be coated, correct?
I would like to be able to power a 55-60w headlight...

You can buy the wire you want at any electrical motor shop.
I rewound one portion of a stator many years ago when I was
poor and could not afford 500 bucks for the stator/flywheel assy.
I bought a spool of coated wire, put a dowel rod through the center
and put it between 2 chairs in my kitchen. I fed the wire through a
hard plastic straw (as a feeder) and wound it up.
I took quite a while and when I was done I put a epoxy coating on
the out side.
It worked fine for the 2-3 years that I owned the bike.
That was on a late 70's XT500.

Do you have any idea what gauge wire you used? There is a formula to calculate how many watts you can get, but the gauge of the wire, and the number of wraps is critical to the calculation - I think...

I have a couple spools of that 17 ga. coated wire.... I never had to try it yet.... shouldn't be rocket surgery...