Two thoughts come to mind: You might be able to drill a small hole in the brush and reattach the lead with epoxy or put a small bolt through the hole with and reattach the brush that way. Find a larger brush and carefully sand or file it down to fit. There are many sources for brushes around.
Re: Motor brushes in reply to DGinVT, 06-01-2014 05:46:59
HI DGinVT That's what I was thinking, but will electricaly conductive epoxy bond to the carbon brush? They seem very slippery. Most of these projects are a one try deal and if it doesn't work, the money spent may as well have gone into buying a new part. But by then it's too late. I've also thought about the mechanical repair with a pin or screw.
Re: Motor brushes in reply to DGinVT, 06-02-2014 05:40:29
DGin VT, A friend suggested cutting a flat piece of copper the size of the top of the brush, silver soldering the lead to it in the center, slip on the spring and install it. I was thinking of adding some electricaly conductive grease or paste between the brush and copper plate. Something like an automotive EC grease which can stand elevated underhood temperatures.
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