Reshaping carbon brushes

Dovetaildave · 22 Jun 2014

Just managed to finish the 20 sheets of 18mm WPB plywood project when the table saw’s breaker started operating every 30 seconds, and worryingly, tiny wisps of smoke came out the side vent of this plastic cased tablesaw.
Finally the saw seemed to begin losing its strength; I presume this is the signs of brush wear. On opening, it seems the brushes are looking very worn and the metal holders even looked slightly overheated at the tip where carbon emerges.
Can’t buy them for this old model; RTS1425 Part no; 0101015005
I have been looking around and there are other brands that have enough carbon to allow re- shaping/re-dimensioning, but the connectors are shaped differently. If I go for the dewalt then ill have to remove 2 mm of carbon along all its length of 19.3 mm.
Q1; Has anyone re-shaped carbon brushes and are there any dos and don’ts when reshaping?
Q2; Has anyone removed and re-soldered (?) the bayonet fitting to the base of the spring/braided cable?

Tools I have; a cheap bench grinder with grey wheels and a selection of files and abrasive papers, soldering iron n solder.

Regards,
Dave

rxh · 22 Jun 2014

A1: I have used abrasive paper for this. Put the paper on a flat surface and rub the brush on it.
A2: A soldering iron can be used. You will need to find a way of compressing the spring while you solder.

rafezetter · 23 Jun 2014

rxh":2ys21ui4 said:
A2: A soldering iron can be used. You will need to find a way of compressing the spring while you solder.

get 2 toothpicks, sellotape and another pair of hands, put the brush on a flat surface then put one TP on the bottom of the brush and put the other in the spring thread near the top and squeeze, this should compress the spring then get helper to sellotape the toothpick ends at both ends - voila spring clamp.

Dovetaildave · 23 Jun 2014

rxh- I was hoping someone would say they've used abrasive paper, I wouldn't have to use the bench grinder, value my fingertips to much.

rafezetter- Your toothpick suggestion sounds good, have you ever soldered this type of item? I ask as I'm not sure if solder is the way, as its difficult to see 'specially without my specs.

Thanks,
Dave