A method for making a dynamoelectric machine conductor bar, compromises providing a plurality of bundled together spiraling strand conductors having surrounding insulation to define a substantially rectangular shape with the strand conductors and strand insulation defining an opposing conductor bar end portion having an electrically insulated gap between the strand insulation adjacent the bar end portion; and applying a filler material to fill the gap to electrically shield the conductor bar end portion and to a greater than 0.080 to about 1.5 inch continuous outer radius surface end portion. A dynamoelectric machine conductor bar comprises a plurality of bundled together spiraling strand conductors having surrounding insulation to define a substantially rectangular shape, with the strand conductors and strand insulation defining an opposing conductor bar end portion; an electrically non-insulated gap between the strand insulation adjacent the conductors at the bar end portion, and an applied filler material filling the gap to electrically shield the conductor bar end portion an applied filler material filling the gap to electrically shield the conductor bar end portion, wherein the filler material defines a greater than 0.080 to about 1.5 inch continuous outer radius surface end portion.