Tool for removing and installing generator and starter pole shoe screws
 

I often see people struggling to remove and install generator and starter pole shoe screws. Here is a short video showing the simple rig I made for my arbor press for removing and installing those screws.

https://youtu.be/aQTjMXQffvY

Re: Tool for removing and installing generator and starter pole shoe screws
 

If one is going to replace the field coils anyway - and not simply remove them to clean the inside of the housing and/or re-seal the coil wrappings - the best way I have found to remove those stubborn bolts is to use a torque and heat the bolt heads until cherry red. Allow them to cool and you can then very easily back the bolts out with a large screwdriver. 'Still won't come loose? Apply heat again. They WILL come out when persuaded by heat.
I have tried all the recommended rigs and special flat blade socket with impact wrench, but heating the bolt heads is by far the easiest and quickest method, let alone less stressful. The bolts can be reused if the heads and slots have not been chuggered up by past attempts to remove them or to stake them in place. To be safe, just order two new bolts when you send for the new field coils. Why get cheap at this stage for the sake of two measly bolts?
Marshall

Re: Tool for removing and installing generator and starter pole shoe screws
 

By the way, when installing the new field coils, they have to seat right up against the generator housing, no gap at all, or else the armature will clip them when it spins, if can even be installed. Don't try to seat the field coils using the slot head bolts. You will not be able to deform the coil frames to match the curve of the housing. Use normal hex head bolts with a breaker bar to do this because you can apply much more pressure to tighten the bolts than you could ever apply with a flat blade screwdriver. Once the bolt cannot be tightened any further, remove it and install the slot head bolts, tightening them as much as you can. Stake them in place with a chisel so that they don't back off, unlikely as that would be.
You will be surprised by how much better the hex head bolts pull the field coils against the generator's housing. Make life a little easier on yourself and follow this advice - this HARD-LEARNED advice. :)
Marshall

Re: Tool for removing and installing generator and starter pole shoe screws
 

I use a tailpipe expander to seat the pole shoes/coils. It presses them tight up against the body so the screws can be easily put in and tightened. No need for other bolts.

Re: Tool for removing and installing generator and starter pole shoe screws
 

Where did you locate the expander ?

Re: Tool for removing and installing generator and starter pole shoe screws
 

Harbor Freight

Re: Tool for removing and installing generator and starter pole shoe screws
 

Thanks for the how to. I have struggled with this screw removal.

Re: Tool for removing and installing generator and starter pole shoe screws
 

Marshall, great idea using the hex heads. It makes sense.

I also use the HF muffler expander.

Re: Tool for removing and installing generator and starter pole shoe screws
 

You can actually see this happen in one of the recent videos by Astra-Werke in which he rebuilds a starter. He doesn't have a way to seat the field coils and he ends up machining the armature down about 1/2mm. :eek:

Re: Tool for removing and installing generator and starter pole shoe screws
 

This is where I got the idea from.

Re: Tool for removing and installing generator and starter pole shoe screws
 

Thanks !

Re: Tool for removing and installing generator and starter pole shoe screws
 

i have used a couple of heavy duty C clamps to seat the shoes to the case. I use an impact screwdriver to seat the screw.