The Essential Guide to Motor Repair | Duke Electric

This guide will focus on sending your motor to a repair shop. This scenario is more likely if the motor is susceptible to its environment, physical space requirements, lifting, and tooling.

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When selecting a motor repair shop, customers usually consider a few essential criteria: fast turn-around time, reliability, and technically skilled staff.

Customers rarely provide specific criteria beyond returning the motor to its original condition. The lack of specification is usually because the customers don&#;t have the background knowledge to identify quality motor repair work.

Getting your motor back ASAP is one thing, but has the job been completed with precision and care?

Customers need the tools and knowledge to recognize quality motor repair and understand things like:

TheSamba.com Forums   Forum Index -> Vanagon -> electric motor rewinding   View original topic: electric motor rewinding Page: 1, 2  Next

DanHoug

Mon Dec 21, 5:06 pm

this is one of those rabbit holes i find myself in....

acquired an old Ebersparcher D2L from a Samba member (thank you!!).. one of the old style, underfloor beheamoths that the Airtronic series replaced. not working, electric motor dead. unobtainium of course. one brush resistor, part of a back EMF braking feature nears i can tell, was burned out. but THAT burned because the armature windings have internal shorts after going thru checking the coil resistance at spots 180 degrees apart on the commutator. THAT was likely caused rusted bearings in the fan housing causing high current draw.

so. i could abandon this project, get an eBay china motor for a different heater and hope things line up, buy a $130 complete clone kit of the Airtop, or drill into this and fix it. never rewound a motor before so why not?

28 gauge magnet wire is on order but the UNwinding has begun. the wires are held to the commutator bars by simple copper tabs that are folded over. they lift up with a sharp knife under them. winding pattern must be kept track of exactly. label everything, write it down, take pictures. we'll see!!

fxr

Mon Dec 21, 5:41 pm

Now that's a proper repair. :) =D>

djkeev

Mon Dec 21, 5:41 pm

Sounds like an insane project that I would take on!

Electricity? Not in my wheelhouse.

Good luck, keep us posted.

Dave

DanHoug

Mon Dec 21, 7:17 pm

thing is, beyond a certain diagnostic point, it ain't electricity. it's Arts and Crafts that someone that can macrame a plant hanger might have a better run at it than i.

anyway. a fun throw away of time.

what i REALLY want to come across is an article describing how much more wonderful these old versions were to the new Airtop series. alas, time might have marched forth with improvements.

Vanagon Nut

Mon Dec 21, 7:21 pm

Oh, my. :shock:

That is cool though.

Take video of the last few unwinds at each winding?

(edit: I zoomed in and better see how the windings are laid out)

"Reassembly is the reverse sequence to removal" ;)

dhaavers

Mon Dec 21, 7:30 pm

I love how some of you guys are crazier than me...

:lol: :wink:

- Dave

skills@eurocarsplus

Mon Dec 21, 8:36 pm

:shock:

having see armatures wound in person once, i think you're crazy



you either have the patients of a saint, or will be a raging alcoholic after this :lol:

spitsnrovers

Mon Dec 21, 8:43 pm

I a past life I worked at an electrics shop as a motor winder's helper.
Taking wires out, counting turns, micrometer measuring wire diameter, building formers to wind new coils on, win ding coils while counting turns, etc, etc.

That meant doing just as you are doing. But you won't have to make formers to wind the coils - just measure the diameter of the wire (without lacquer enamel), and measure the length. Then wind it back into the slots - presumably protected by the paper sleeve inserts.

You're certainly going about in a methodical manner. Congrats.
And, there isn't a motor repair shop around (that I could find) that will rewind a small motor as you have.

Yellow Rabbit

Mon Dec 21, 9:00 pm

:popcorn: :D

alaskadan

Mon Dec 21, 9:10 pm

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Custom Brushed Aluminum Stickers - Go metal

Thats cool. Reminds me of my glass shop days. When an edger or beveler motor would go down I'd take them to a guy who rewound them for us. He did BIG motors compared to our puny little 5 to 10 hp motors as well. Like for elevators and such.Cooked them in a kiln out back to burn off the varnish. Specialty trade for sure anymore. He sells real-estate now.

Steve M.

Mon Dec 21, 9:42 pm

What...you never built a ship model as a kid?
You know the ones where they gave you all the pieces of the motor and you had to build the motor.

DanHoug

Tue Dec 22, 6:46 am

Steve M. wrote: What...you never built a ship model as a kid?
You know the ones where they gave you all the pieces of the motor and you had to build the motor.

oh, yeeeeaaaah. forgot about those. never got mine to work <Gulp>!

thatbaldwinlife

Tue Dec 22, 7:32 am

Impressive that you are willing to take this on versus buying something else. This is what more people in the world need to do to reduce the consumption and "throw away" society.
nate

DanHoug

Tue Dec 22, 1:03 pm

Vanagon Nut wrote: Oh, my. :shock:

That is cool though.

Take video of the last few unwinds at each winding?

(edit: I zoomed in and better see how the windings are laid out)

"Reassembly is the reverse sequence to removal" ;)

i kinda freaked out about that too... but it's very sequential and my chart helps. i'll photo/video the very last few turns because getting it started correctly will be the entire key. what's interesting is that it is one continuous piece of wire but electrically 7 different coils as it makes electrical contact thru the commutator bars. other motors spot weld the copper onto the commutator, fortunately this is just tabbed.

i can't believe the minds that came up with this stuff... brilliant people out there thru the times.

Vanagon Nut

Tue Dec 22, 1:45 pm

DanHoug wrote: Vanagon Nut wrote:

Take video of the last few unwinds at each winding?

(edit: I zoomed in and better see how the windings are laid out)

.... what's interesting is that it is one continuous piece of wire but electrically 7 different coils as it makes electrical contact thru the commutator bars. other motors spot weld the copper onto the commutator, fortunately this is just tabbed.

i can't believe the minds that came up with this stuff... brilliant people out there thru the times.

It is pretty amazing really. But much like something like assembler or machine language at low (lowest?) levels of computer parts, motor windings aren't something younger generations think about, much, I'd guess. (not that I know anything about that computer stuff but a friend, who is really quite brilliant, told me about it back in )

Yeah the "lay of the land" in how each coil sits over the other was what I was seeing as a potential problem spot(s) in re assembly.

Oh I see now. One piece of wire that hooks around each tab. Neat! Very clever.

So the wire is enamel coated?

Neil.

DanHoug

Sat Dec 26, 5:27 pm

well... a success! the motor Chooches! wound it with 28 ga. Polyamideimide-Coated Copper Magnet Wire from Remington Industries. it was slightly thicker than the OEM, which was probably 29ga and a thinner insulation. filled the armature valleys up pretty good, realized i should have been winding a bit tighter after the 3rd winding but i made it. but the motor spins, has low current draw, starts up at low voltage. everything says success so far!

waiting for the winding varnish to dry now.

djkeev

Sat Dec 26, 6:04 pm

=D> =D> =D>

IdahoDoug

Sat Dec 26, 6:18 pm

Friggin Awesome! Some things have their own value. I'm currently hand lapping the valves on another vehicle with lapping compound from in an antique and very cool metal container. Coulda used new stuff but I like tradition and doing things like you clearly do as well - the old fashioned way. A nod in your direction, sir!!

Doug

chompy

Sat Dec 26, 6:19 pm

Skookum! Let us know how it keeps up!

Edit: friggin autocorrect!

ALIKA T3

Sat Dec 26, 7:34 pm

This is rad!

I considered doing similar for the rear wiper motor but I never had to bc I have spares...
Out of curiosity, how long was all the windings? How long did it take to wind up?

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