Has anyone here ever rebuilt a generator?

[Jack Miller CLC# 24441]

I just pulled out my generator as it wasn't putting out enough power to keep my battery going. I just remembered that in 2004 my rebuilder retired and I bought generator bearings and new brushes for mine when the time came which is now.
Should I attempt changing the brushes and bearings myself or send it out on Monday? It looks pretty straight forward. Anyone here with thoughts or experience on this job?
I have a few cars that I let sit as I was doing my last body off frame on a 1967
Pontiac GTO. I am going over my cars that sat now so when done I can finish
GTO before winter. Just turned 64 and frame off jobs are for the young people.
This Cadillac was a body up with body bolts loosened so I can paint frame back in 2001. Almost every part was removed and put back
With all new rubber as this car sat for over 25 years when I got it. Time ruins rubber and seals but I was semi lucky. Car only has 43,000 on it with documents.
Thanks
Jack
1961 Cadillac

[TJ Hopland]

Sounds like you are pretty hands on and must have a decent assortment of tools.   Generators are not too bad to refresh.   Where you would likely run into not having the tools is if the commutator (area the brushes run on) has significant wear or if there is issues with the windings.  If the commutator is in good shape you can likely get away with just cleaning and a light polish.  If its worn then its likely a job for a specialist.  Same if something needs re winding.

[Dave Shepherd]

Check the mica between the commutator segments,  if the copper is worn down where the mica is above the segments, this requires  cutting down thE mica so the brushes don't touch them.

[Thor]

I did this a few months ago.

Symptom:  Gen light blinking and wouldn't go out.

Figured, what the heck?  Tear into it and get a look-see.

The brushes were worn so much that one cocked over in it's holder, the bearings were renewed as a matter of course - what was there were sealed bearings also.  Weird thing was, the dimensions were metric!

The commutator was worn a bit and needed turning.   Chucked it up in a lathe and started with skimming passes... kept this up and discovered that the surface was bowed down in the center.  Kept skimming and discovered that two copper bars on one side were a bit lower that all the rest.  Kept skimming until all was shiney.... then took a hacksaw blade with the kerf ground thin, and hand drew the mica until sufficiently undercut.

The commutator passed the connections test, so I skipped the step about checking the field wires and put it all back together, then polarized the field, and connected all wires, and the car behaved very well.  I blame-a myself for not having checked this at purchase.

Have fun with all this,
Randy Bergum
26162
1960 Eureka Hearse

[Dave Shepherd]

Nice job!

[bcroe]

The brushes were worn so much that one cocked over in it's holder, the bearings were renewed as a matter of course

The commutator was worn a bit and needed turning.   Chucked it up in a lathe and started with skimming passes...
Randy Bergum   

Thanks for the run down on "how to".  When my brush got that short, it broke
my brush holder.  I decided to replace brushes based on mileage to avoid that
sort of thing; the beginning of my periodic maintenance.  If the commutator is
in decent shape, the job gets pretty simple.  Bruce Roe

[Jack Miller CLC# 24441]

I bought over 10 years ago from a retiring generator starter rebuild shop new brushes and bearings. I opened the generator up, soldered one wire, took 2,000 w&d paper and cleaned the copper on armiture, left original bearings as original were still good (thank goodness as I think they get pressed in) but lubed bearings. I replaced the old worn brushes, cleaned the inside with electronic cleaner and checked with multi meter armature and brushes paths. Put all back together and works great, pushing out 14.6v now and red light off dash.
Thanks
Jax
1961 series 62