ARgh thats a pain!

[alexanderfoti]

I pulled off the flywheel yesterday, for some modifications (removing fins and having a general play, as I have a replacement on its way).

And my rewound stator has been rubbing on the inside of the flywheel housing I am no way going to rewind the whole thing, so hopefully a bit of solder and some pliers with rubber round them will help me coax that small gap I need to make then clear the flywheel.

Pain though!

[XLerate]

Sorry for your pain, Alex! Maybe search out some wooden or plastic tools like popsicle stick, tongue depressor, piece of plastic or whatever to manipulate your wires. Skinny vinyl tubing over a piece of coat hanger might do it? Also clear fingernail polish can serve as an insulator wire coating.

If you get real lucky instead of a popsicle stick you'll find a pop-cycle stick, just right for the job...

[alexanderfoti]

You had the same thoughts as me!

I used a caliper to measure the thickest "bobin" that wasnt scraping the flywheel, and I then used a rubber hammer and a rubber mat to hammer the ones that were too wide into submission!

I then covered it with epoxy:



Here is the damaged from the magnet thingy:



unfortunately, i didnt take a picture of the stator before it was worn away, but it had basically worn about 25% of 2 or 3 wires on 2 bobbins. So nothing too bad. Glad I caught it early.

[XLerate]

Great, hope it works for ya, buddy!

[alexanderfoti]

Flywheel back on and 10+ amps of charging! Phew!

[XLerate]

Congratulations on your clever and successful repair, buddy! Good news, many miles of smiles to you!

[Diesel Dave]

Reminds me of the time I discovered a smashed bobbin in the Tigers' alternator.......the day before the ferry heading for the Hamm Rally.

I cut out the wire and soldered a bypass - worked for over a year before I replaced it.

[alexanderfoti]