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18th Apr 2014, 10:16 PM #76
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18th Apr 2014, 11:49 PM #77.
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- Nov 2008
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An Eventful Day!
I kept my appointment and Bob started probing and it turned out the star point was close to where I thought it was. The three wires were twisted together and their ends concealed within the black spaghetti.
The long section of yellow spaghetti covering one of those three wires was more difficult to remove than hoped for. That difficult that the 0.2mm wire snapped off with about 8mm projecting from the side of the windings. I said to Bob that I'd take it back home for a fiddle. With a 7x loupe jammed into my eye socket I went to work. To remove the insulative coating from the wire in preparation for soldering, I held its outer end with a pair of tweezers and scraped the coating off with a scalpel blade. The wire had a kink in it. It snapped off again at the kink accompanied by a " you've got to be ....ing joking!!". Turned out to be a frequently uttered exclamation throughout the course of the afternoon!!
There was about a 6mm projection of wire remaining, certainly insufficient to wrap around the multi-strand wire Bob had given me . I buried the wire amidst the strands and soldered the connection. I tested the joined wires for continuity before covering them with heat shrink. The second joint was uneventful and so I thought would be the final connection. That wire too featured a kink and snapped at its location leaving a wire too short to easily access with a combination of the multi-strand wire and the soldering iron tip. There just wasn't enough room. I formed a hook on the stator wire and also a piece of heavier gauge wire and soldered them together.
The most nerve racking aspect of the job was preventing work hardening of the thin wire. The lashings you see in the photos are temporary. I used Oral B dental floss, mint flavoured.
I have another appointment tomorrow where Bob will check my handiwork and megger test the stator. Fingers crossed.
Bob
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18th Apr 2014, 11:49 PM #78Senior Member
- Join Date
- Oct 2008
- Location
- blackburn vic
- Posts
- 297
Crimping Pliers
Jaydee Auto Cables in Bayswater have a large range of crimping pliers for what it is worth.
Roger
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18th Apr 2014, 11:54 PM #79Member: Blue and white apron brigade
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- Feb 2006
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- Perth
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- 7,183
Champion work Bob!
I don't think the photo's really show how thin those wires are, of course not to mention how fragile they seem to be if the are moved too often.
See you tomorrow.
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19th Apr 2014, 12:14 AM #80Most Valued Member
- Join Date
- Jul 2010
- Location
- Melbourne
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Great work Bob, I hadnt given wire size a thought.
Thanks Roger I can see me visiting them soon..... didnt know there was a second row of shops behind the front ones.
Stuart
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19th Apr 2014, 01:24 AM #81
Hi BT,
The quick way of removing the enamel is to burn it off, a cigarette lighter does nicely, and then just wipe off the carbon, and you've got clean copper, plus it anneals it a bit.
Ray
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19th Apr 2014, 06:01 AM #82
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19th Apr 2014, 09:19 AM #83Golden Member
- Join Date
- Apr 2009
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- Ballina N.S.W.
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- 644
Great work BT & BobL looks like you had to preform micro surgery with all that fine gear. Fantastic photos as usual Bob, I hope after all your efforts this motor works out OK for you.
Bob
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19th Apr 2014, 09:38 AM #84Member: Blue and white apron brigade
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- Feb 2006
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I haven't had a problem with the enamel but some of the goops used to seal the fibreglass sleeves to the coils. In most cases I heat the ends of the wire together and then using a dab of brazing flux on the rod seems to work, but sometimes the goop doesn't seem to burn off even with a butane torch and I've had to resort to fine grit paper to get it off, The worst case was a common point additionally wrapped in what looked like a a fibreglass sticky tape which left a glossy black residue on the wires when it was heated.
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19th Apr 2014, 09:49 AM #85Member: Blue and white apron brigade
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- Feb 2006
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- Perth
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Cheers KF, What AB didn't say was that I was the one that broke the first wire - not a good feeling as you can imagine.
We confirmed the common point easily enough and then started to strip back the fibre glass insulation and managed to tease out two of the three wires fairly quickly to the point where we had a plenty of free wire to play with.The third wire was buried inside a length of insulation firmly stuck down to the coils. I managed to get the insulation away from the coils and disconnected from the other wires, but while removing the insulation from the 3rd wire the 40 mm piece of wire and insulation came away in my hand. I wasn't even pulling on it, - it just broke! The problem was it broke right back and underneath a pile of other insulation so there is bugger all left to see with the naked eye to work with.
Anyway, thanks to AB's skills under the Loupe he managed to tease out enough wire to get a hook on it.
I have to say I felt a wee bit better to hear that he broke some wires as well.
I think I'll stick to bigger motors from now on but I have a 1/8th HP I would like to have a go at but that is a new motor so hopefully the copper should not be so brittle.
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19th Apr 2014, 11:34 AM #86.
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- Nov 2008
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- Perth WA
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- 71
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I will admit to this being one of the trickiest and probably one of the most nerve racking jobs I've tackled of late.
I don't think I could have introduced a naked flame into narrow space between the housing and stator without causing irreparable collateral damage.
Here's a shot of the arsenal of tweezers I used yesterday along with the indispensable third hand and the all important loupe.
2014-04-19 005 (Large).JPG
Dean apologised for hijacking the thread with the excursion into crimping. No apology was required. Crimping is something I've always wondered about. The only crimping tools I have are a next to useless Utilux jack of all, master of none and a slightly better Yankee version of the same thing. The following photos show how I use it. And I could very well be using it incorrectly.
BT 2014-04-19 011 (Large).JPG2014-04-19 006 (Large).JPG2014-04-19 007 (Large).JPG2014-04-19 008 (Large).JPG
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19th Apr 2014, 03:29 PM #87Member: Blue and white apron brigade
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- Feb 2006
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- Perth
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Well, AB has been and gone - all Meggered fine, coil resistances all add up and make sense.
Whew!
Now it's back to Bob to sort the end cap out.
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19th Apr 2014, 08:11 PM #88
Thanks Bob for allowing me to hijack your thread.
After some searching I have a short list of the following.
http://www.ebay.com.au/itm/161262450928
http://www.ebay.com.au/itm/0-5-6mm-P...item2a39c32d6e
http://www.ebay.com.au/itm/CRIMPING-...item3a78ee2eb0
http://www.ebay.com.au/itm/Electrici...item5d4a752ff9
I am leaning toward the last one as it is the most versatile.
Does anybody have any suggestions or comments about these choices.
Dean
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19th Apr 2014, 11:38 PM #89
Nicely done BT, your surgical skills are impressive.. you should consider a career in medicine....
Dean,
I already linked to several suitable crimpers, for uninsulated terminals you just need to look at the shape of the jaws to see if they will roll the tabs towards the center of the crimp, then you look at the size to make sure it suits your terminals and wire gauge.
Here's one I use a fair bit, it's a Harwin crimper, which crimps the insulation and the wire in one go, I did a quick terminal to show what I mean..
DSCN0040s.JPGDSCN0041s.JPGDSCN0042s.JPG
Don't mind the wire strip length in the middle picture, I trimmed it before crimping. What I wanted to show is how the crimp folds towards the middle.
Ray
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20th Apr 2014, 09:04 AM #90Member: Blue and white apron brigade
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- Feb 2006
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- Perth
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Thanks for ferreting those out Dean. I started looking on ebay and was overwhelmed.
I like the look of the last one as well.
Here are a couple of interesting sets of crimpers.
Deluxe Magnetic 7 piece jaw set
http://www.altronics.com.au/index.as...=item&id=T2177
Buy the crimper and then only the jaws you need - choose from 6 different jaws.
http://www.jaycar.com.au/productView.asp?ID=TH1950
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