I tried to reinstall the upper generator brush hold-down spring on my generator that fell off (after I unclipped it from the brush). The spring does not now have enough tension to press down on the end of the brush.

When I compare this spring with the lower brush spring currently installed, the lower one appears to have a much tighter coil than the upper one that fell off. Is there some special tool (or trick) that is used to wind the spring tighter before or after installing it?

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Dave Wildrick
Houston, TX
#10230
64C coupe
65C coupe

Here's a reference from the starter brush plate. I think it's a similar setup. The picture shows two "free" springs -- one mounted correctly and the other not. I used a spring hook to pull the spring clockwise to load against the brush (after the commutator is installed).

The other two springs are in the correct positions against the brushes, but there is no tension as there is no commutator and shaft pushing them against the spring yet.

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Thanks.
Your red arrow shows exactly the path I believe the end of my spring needs to take to get in the correct position. I tried a forceps and a few other implements but could not do it with the generator all together.

Where do I find a "spring hook?"

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Dave Wildrick
Houston, TX
#10230
64C coupe
65C coupe

O.K. James, I Googled on "spring hook".
They come in a variety of sizes. What size or type would you recommend?
There's not much room to work to pull this spring into place.
Thanks.

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Dave Wildrick
Houston, TX
#10230
64C coupe
65C coupe

You can probably find them at an electronic store -- Frys. You can buy them on the web too. In the absence of one and for a one-time job, you could probably make one. You also may be able to loop a piece of 22 gauge wire around it. The thing is, you have to hold the center down while flexing the spring up and around...to get it into the right position.

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There's another tool for this too. I saw one being used in a generator repair shop. It uses the center of the spring as the attach point. You put the end of the spring on the brush and tool attaches to the center of the spring and you twist the center and push down when aligned to the anchor.

Good luck!

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You can fabricate a hook out of a short piece of stiff wire. Put a loop in the other end to facilitate holding it. Pull the spring around to the correct position against the empty brush holder and then use the hook to hold the spring back while you load the brush. Easy job.

Cheers,
Wes

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A bicycle spoke already has a bend and a small nipple on the end. It can work good for this job. I also use an old stainless steel dental pick that my dentist gave me years ago.

Good luck,
-Greg

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I've always made them from a fairly long cotter pin, just bending the hook from the long side with a needle nose plier, as the steel is rather soft...It always works for me, and usually available...
Mike

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Thanks guys for all the good suggestions.
I'll fabricate something and give it a shot on the generator I just pulled off my 65C coupe, where I dropped the spring when trying to change the upper brush.
It will have to wait till I get back from my trip to an Arizona Outlaws event--leaving Houston tomorrow a.m.

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Dave Wildrick
Houston, TX
#10230
64C coupe
65C coupe

Well I got back from the Arizona Bulldog Rennen and took another look at the generator with the brush problem. I used a piece of piano wire to pull the spring on the upper brush up where it belongs, and then I replaced the lower brush as well.

I installed the generator/fan in the car I didn't take to AZ (the 64C coupe, whose generator I stole to take the the 65C coupe to AZ). Fired it up, and the generator light goes off at about 700 rpm. Happy about that since brushes are a lot cheaper than generator rebuilds.

_________________
Dave Wildrick
Houston, TX
#10230
64C coupe
65C coupe