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| tutelar-rc | Veteran - Location: Nobleton, Ontario - Canada - |
How to Repair the Broken Wire Lead
This photo shows the location of the broken wire. The edge of the motor housing rubbed through the insulation and caused the wire to break – this is normally caused by a poorly balanced tail or bent shaft extension.
Removing the End Cap
The key to removing the end cap, is to establish a method to push the shaft straight back, so the shaft does not become bent.
I modified my pinion puller by drilling two holes in the main housing as shown.
Notice that I made the right hole into a short slot to accommodate the slight difference between my hole-to-hole center and the motor screw holes.
Screw the motor onto the pinion puller and assemble the pinion puller.
Note: I cut off all wire leads at the point where they enter the motor housing
– DO NOT DO THIS! Leave as much wire on the motor as possible. Working inside the motor housing to solder the remains of the wire is difficult.
My recommendations:- Only repair / replace the wire lead that is broken – leave the other wires intact.
- Remove the insulation from the wire to allow the wire length to be as long as possible.
A couple of turns will pop the end bell off the motor housing. This requires very little force.
The motor housing is now open providing access to the wire leads.
Soldering on New Leads
As noted above, it is quite difficult to work inside the motor housing to solder on new leads. Only replace the lead(s) that are broken.
There are 2 winding wires that extend out the end of the motor to become the motor leads. When you solder on the new leads, make sure you connect to both of these wires.
I re-used the wire leads that I previously cut off, to solder back onto the winding wires.
Hints to get a good solder connection:- the winding wires are coated, so the coating must be removed – I used a small piece of sand paper to scrape the ends of the wires
- I then used tweezers to gently twist the 2 wires together – too much force, and you will break a wire
- use a small amount of solder paste and a small electronics soldering iron to “tin” the wire leads
- when both the winding wires and the new leads are “tinned”, put the wires together and use the heat of the soldering iron to join the wires together
- you do not need a lot of solder for a good joint
Finishing Up
Use heat shrink tubing to insulate the leads. Make sure that the heat shrink tubing goes all the way over the solder joint, butting right up against the motor windings. This will ensure you do not get an electrical short.
Place the end bell back on the motor housing and press back into place. I used a small block of wood with a hole drilled in it for the motor shaft to go through. I then pressed it on in my vice – again, only a small amount of force is required.
The finished repair, just waiting for the tie-wrap around the motor to hold the wire leads in place.
Improvements
To reduce the risk of the insulation wearing off and the wire breaking, I suggest that you: - use a small amount of silicone around the wire leads where they exit the motor housing,
- tie-wrap the wires around the motor housing to reduce movement of the wire leads
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| 09-08-2007 04:50 PM | | | |
