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Discussion Starter #1
Hello everyone. I am ready to assemble a pancake motor for my TYCO made in Hong Kong engine. I was wondering if anyone has a "trick" or easy way to get the carbon "dots" and springs to stay in place when joining the side to the motor. I have included a photo of the motor.
 

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Discussion Starter #3
Install brushes and springs in Pancake Motor

Dan, Here are two photos. 1. Shows the armature and the side that joins it with the electrical connections. 2. The same of the armature but the other of brush and spring cavities.
 

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Dan, Here are two photos. 1. Shows the armature and the side that joins it with the electrical connections. 2. The same of the armature but the other of brush and spring cavities.
From these two photos, I would place the brushes into the two indents provided for them , then I would lower the other half of the motor onto it.
I'm not sure if the two plates covering the outside of the brush holes are the actual springs that apply pressure to the brushes, and keep them against the armature.

If in fact there are two springs that go behind the brushes, I would place the springs and brushes into the frame, then place a business card over them to hold them in place. You will have to cut a slot in the card to allow the card to be slid out, once the armature shaft enters the bearing once I had the other half of the motor in place, Carefully slide the business card out, all the while keeping slight pressure on the armature half so nothing falls out of place.

Dan
 

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Discussion Starter #5
Install brushes and springs in Pancake Motor

Dan, three things. 1. There are actual springs (you need a magnyfing glass to see them) behind the brushes which are almost as small as the springs. 2. The contacts you see do not put pressure on the bushings or springs, they are just metal contacts for the springs. 3. I found a video on youtube that a guy posted showing a jig out of a index card to install these exact springs and bushings in the exact motor. Unfortunately, I tried it and some how one of the springs decided to take a leap and it is now gone forever! I have two springs on order.
 

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Install brushes and springs in Pancake Motor

Dan, I found a way to install the springs and brushes that is better and easier than the guy on youtube. Here is what I did: I got two pieces of 1/8 inch Christmas ribbon. I put a slip knot into each piece with a circle of ribbon slightly larger than the spring and brush holder. I then put a spring and brush in one of the holders, slid the flat 1/8 inch ribbon between my finger holding the spring and brush in place. While holding the ribbon on top of the brush I pulled the slip know tight. Then I removed my finger and the spring and brush were securely held in place. I repeated for the second spring and brush. I then put the two pieces together and tightened the two screws just short of snug. I then cut the ribbon loop, pulled the ribbon out of the joint on each spring and brush. I tightened the two screws and tested the motor. It ran just fine.
 
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