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Making Correct Commutator Rings


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  #1  
Old 01-19-2017, 05:52:33 PM
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Turbo Turbo is offline
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Default Making Correct Commutator Rings

I finally sourced some phenolic tube that is very close to the correct size. This material is a little hard to find and is expensive. This is closest I could find after a lot of searching. It has a 2" OD and 1.5" ID. I made dimensions based on a reproductions made 10 or more years ago. They had a 2.160 OD. I have an original that is a little rough that has a 2.050 OD. I think given how hard this stuff is to find .160 difference should be fine and after cutting one out it is hard to tell the difference without breaking out the caliper. I plan to make 30 or so. My question is what is the original width? My original is .875 wide and the early repop. is 1 inch. The narrower original I have has just enough width to catch the contact. A little wider would be better I think. Also the repop has a flat groove machined in it to accept a flat brass strip which was machined round after it was screwed in place. The original has a convex groove machined and a formed brass strip screwed in place which I know is correct. I am trying to figure out how to machine this convex groove. It seems simple but I cannot find anything that will work to machine it. Does anybody have a good idea?? Here are a few pics of my progress so far.
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Old 01-19-2017, 06:47:36 PM
Jake Jacobs Jake Jacobs is offline
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Default Re: Making correct commutator rings

Dovetail cutter endmill will get you the two groves.
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Old 01-21-2017, 05:59:06 PM
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Default Re: Making correct commutator rings

Thanks Jake, I looked at dovetail cutters but they will give me a flat angular groove. I need a cutter that will give me a rounded groove.
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Old 01-25-2017, 05:38:53 PM
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Default Re: Making correct commutator rings

Just finished one today. Here are a few pics. It turned out pretty good. I think I have a system down for cutting the groove with a small 3/16 end mill that works pretty well. I will be making more so if anyone is interested let me know. They will be $35.00 a piece.

Thanks Travis.
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Old 04-14-2018, 12:18:05 PM
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Default Re: Making correct commutator rings

I want to let everyone know I have 1 hp rings now available too.
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