Hi and welcome to this forum.
I'll try to answer your questions the best I can.
1) Which magnet do you mean. The stator magnet or rotor magnets?
Anyway, both the rotor and stator magnets will be keyed in place and cannot move out of position.
If you download the ealier posted F.B.D.I.S.S.M_v2.2_blueprint.zip you can see the stator steel layout with its keys.
In the earliar posts I hadn't finished the rotor magnet key holding mechanism. But you can see the rotor keys in the new pic.
2) I have chosen stainless steel to hold the stator magnets because this is easy to precision cut by laser.
This material is also strong enough to withstand the attracting forces between stator and rotor magnets.
The rotor will be made of light weight aluminum and magnetic back iron to enchance the magnetic properties of the rotor magnets.
3) I have used a formula that calculates the distance and angle in certain positions and then I use magnetsales
calculator to calculate the force.
http://www.magnetsales.com/Design/Calc_filles/PullAndPushBetween2RectMagnets.asp I enter the distance of both ends of the rotor magnet towards the stator magnets and get the difference in force.
Then I split it by two to get the mean value. And this I convert it into ft-lbs and enter it into the Hp formula.
4) I have calculated many types of spirals to get the most powerful twist towards the narrow end position.
When I chose to split the spiral in two halfes to balance the force against the ballbearings I got even better rotational twist force.
Finaly I couldn't get more force from the spiral angle. Further calculations just shifted around the area where the most torque was
created. Then I was pleased and designed the spiral in my cad system using the best output from my torque formula.
5) A Flux Booster Controller is simply a special type of controller I have designed. It's main purpose it to get rid
of the long charge time of a high inductance coil. It has lot's of other features as well, such as being self runner prepared.
An ordinary strong electro magnet can have a charge delay as long as 1 Second before reaching full magnetic field.
Using the Flux Booster it will minimise the flux build-up time to less than 200uS = 0.0002 Sec.
Inside a fast spinning motor this is very crusial to reach maximum performance.
Another feature is that it also cuts down on power requirement to run a coil at high speed.
Once initialized it just takes static power to maintain the strong field of the electro magnets.
Typically it lowers the power need of the coil by 10-15 times. When going for overunity this is a good feature to have access to.
You can read more about the controller here:
http://www.overunity.com/index.php?topic=2386.msg38801#msg38801I hope this clear things up for you.