Fix Your Generator Fast!

Table of Contents

1. Introduction
2. The Story of the Starter Generator
3. The Voltage Issue
4. The Discovery and Solution
5. The Replacement Parts
6. The Process of Fixing the Generator
7. Installing the New Stud
8. Replacing the Brushes
9. Testing the Generator
10. Conclusion

The Story of the Starter Generator

In this article, we will explore the fascinating story of a starter generator from 1951 that was once a bathtub. Yes, you heard that right! This unconventional generator was made by repurposing old bumper cars, resulting in an interesting and unique piece of equipment.

Introduction

Have you ever come across a 1951 starter generator made from an old bathtub? Well, in this article, we are going to take a deep dive into the intriguing world of vintage generators. We will discuss the story behind this peculiar creation and uncover the issues that led to its disassembly. Join us as we explore the journey of a generator that once served a completely different purpose.

The Voltage Issue

The generator in question was not performing up to par, as it was only outputting a measly 1 volt instead of the expected 6 volts. This significant drop in voltage indicated that there was a problem that needed to be addressed. To get to the bottom of the issue, the generator had to be taken apart and examined further. The underlying cause of the low voltage output needed to be identified in order to fix the generator and restore it to its former glory.

The Discovery and Solution

Upon dismantling the generator, a crucial discovery was made. One of the wires that should have been attached to a specific stud was found to be disconnected. This wire was originally soldered to the stud, but over time, it had become detached. The culprit behind this detachment was a cracked insulator that failed to prevent the stud from rotating. As a result, the wire had come off, leading to the voltage issues experienced with the generator.

To rectify the problem, a new stud was ordered, along with a set of brushes and a new capacitor. Although the brushes and capacitor might not have been strictly necessary, they were replaced while the generator was already disassembled to ensure optimal performance. With the replacement parts in hand, the next step was to fix the generator and bring it back to its original functionality.

The Replacement Parts

The new stud, brushes, and capacitor were essential components in restoring the generator. The stud, which came with a wire attached, was designed to prevent the rotating motion of the stud and ensure a stable connection. The brushes, although the old ones still had some life left in them, were replaced as a precautionary measure, guaranteeing the longevity of the generator's operation. The new capacitor, although not obligatory, was also installed to enhance the overall efficiency of the generator.

The Process of Fixing the Generator

To begin the repair process, the generator was thoroughly cleaned to remove any accumulated grease and dirt. This step was essential to ensure a clean surface for the replacement parts to be installed properly. After cleaning, the new stud was positioned and secured in place using a specific alignment tool. This effectively prevented the stud from rotating and ensured the stability of the wire connection.

To create a secure connection between the wires, a small piece of the original wire was soldered to the wire attached to the new stud. By doing this, the larger bolt of the stud acted as a heat sink, facilitating the soldering process. This method proved to be a more convenient approach compared to unsoldering the wire from its original location.

Installing the New Stud

The installation of the new stud was a relatively straightforward task. The hex on the stud engaged with the hex on the insulator, effectively preventing any rotational movement. Additionally, an insulating washer was used to secure the top part of the stud, ensuring optimal performance and stability.

Replacing the Brushes

The brushes, which play a crucial role in the generator's function, were replaced with new ones. These brushes were installed at an angle, mirroring the orientation of the old brushes. The spring-loaded mechanism of the brushes allowed for easy insertion, making the replacement process uncomplicated.

Testing the Generator

After all the repairs were completed and the replacement parts were installed, the next step was to test the generator. Unfortunately, the team encountered a slight hurdle as they did not have a device that could spin the generator at the required speed for accurate testing.

They attempted to test the generator using a small motor that turned at around 1,700 revolutions per minute. However, this speed fell short of the necessary RPMs. For an accurate assessment, a generator requires a considerable amount of amps, which can only be achieved when it spins at the appropriate speed.

Conclusion

In conclusion, the journey of the starter generator from an old bathtub to its current state showcased the intricacies involved in repairing vintage equipment. Through careful disassembly and inspection, the team was able to identify the issue and find a suitable solution. By replacing the faulty parts and conducting a thorough cleaning, the generator was successfully restored to its former functionality. This tale serves as a testament to the ingenuity and resourcefulness of individuals in the field of restoration, as well as the importance of attention to detail when working with vintage equipment.