Hi Again.

Julian sent me a knackered and stripped rotor to play with. Photo should be attached That I shall deal with in due course. I am attaching the pics.

Having also carried out various checks I have come up with( bear in mind I am only a user not in any field an expert) what I consider to be probabilities.

1. Assuming the front sprocket is fully "home" Once the Alternator centre boss is in place and torqued up it cannot possibly move laterally on the shaft.

2. Internally the alternator components are not fixed it place but only held by the magnets and the zinc??? casing.

3. Rotary movement between the magnets/casing is impossible-for the square magnets to
move on a square base it would need to increase the diameter of the whole item.

4. The only possible area of movement is the magnets sliding sideways, that is possible. They could also twist an extremely small amount probably no more than 001".

5. My thoughts are--Possibly the only part/s that is moving is the skirts of the casing.

6. Any rotational movement must be the boss on the shaft, likely as a result of inacurate broaching of the keyway.

7. Repairs? forget welding. If you use an electrical method you risk murdering the magnets. If you use a torch you risk melting the whole issue. So I would suggest the method of repair I have used in previous post is probably the only viable.

8. There are several ways of achieving that repair. At a later date I shall consider putting a plate on back and front and bolting it through with something like 3mm bolts/screws. Providing available clearance between alternator and front sprocket.

As you will see from pics the "shoes" are not solid but consist of about20 "blades" held by a cetral long rivet. The rotor that is already stripped I am going to attempt to weld/braze together and use without a casing(luck requested). Not for a while---busy.

So thats it in a nut shell. Phew Any Q's just ask

Mike

  Try again with pics

If you use heat in repairing one of these rotors, I am sure it will demagnetise the magnets to some degree. This must have happened during the original manufacturing process and I assume Lucas would have needed to re-magnetise the magnets afterwards. Using epoxy to make a repair would obviously avoid this problem!

 

I agree with that and is a consideration for the "rebuild" of the stripped rotor. I shall not even consider any welding or other heat on a built up rotor just the large washers and screws/bolts/ self tappers as per previous

Mike

Hi,
    Some failures:

Hi,
    I think I will replace rather than repair,

Best wishes...

 

Hi Bess

I intend to run the one that I've repaired on next machine rebuild. However I fully understand why you would decide not to repair.

Take acre and thanks again

Mike