Can a sticky cutout be repaired? FOLLOWUP

[Elcastor]

Originally Posted by Tom Wesenberg

Cutouts aren't too bad to work on. I cut a hole in a block of wood to hold the cutout upside down. I use a very sharp thin chisel to split the spot welds, then the cover can be pried off. Once the cover is removed you can straighten the bent metal from using the chisel on it. Use compressed air to blow the metal specs off the top of the armature, where they like to collect due to the magnetism. File the contacts or sand them smooth, then set the open air gap to .020" and make sure when the contacts are closed that the top of the armature (magnetic coil) still has a thin air gap.

The cutout on the right and the bottom picture shows an original cutout and the quality it has over the left cheapo cutout.

The cover will fit tight and doesn't need to be soldered or spot welded to hold it in place.

How do you clean up the inside of a cutout so nicely as shown in these pictures?

[Tom Wesenberg]

I use the small wire brushes similar to a toothbrush, and compressed air. Actually the inside stays pretty clean, except sometimes fine metal grit collects on top of the electromagnet. It's easily blown away with compressed air.

Most of the repros I don't waste time trying to fix.

[700rpm]

I put the diode cutout in and haven't had any problems since.

[Purdy Swoft]

Good move !! Thanks for the follow up.

[Mike V. Florida]

Tom, never having seen a cut out opened in person, could his problem be as simple as residual magnatism in the core of the relay?

[Tom Wesenberg]

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Originally Posted by Mike V. Florida

Tom, never having seen a cut out opened in person, could his problem be as simple as residual magnatism in the core of the relay?

When the current flows backwards (generator not charging and contacts still closed) the magnetism is reversed and should open the contacts. Some of the cheap repros will burn at the contacts and stick closed. If the contacts aren't burned then I'd try adjusting the spring for a little more opening tension. Just don't make it too tight, because the contact should pull closed by 6 volts.

[marc hildebrant]

I currently have an alternator and did not pay much attention to the design of the cut-out and how it worked. I have to say that I'm impressed with the design of the cut-out. The use of two coils and the way that Ford designed a simple circuit to perform a complex function is quite impressive.

Note the way that he used the many turns with fine wire. Very nice enginering.... Magnetic fielded strength is related to the current and the number of turns around the pole piece. Many turns created a strong field that was balanced with the fine wire that reduced the current to just the right level to pull in the relay but not enough to hold it long.

Very clever.

Marc

[SteveB31]

If any of you are needing a restored original cutout, we have a couple hundred of them, restored, tested, cadmium plated and ready to install for $65 each.

Steve Becker
Berts Model A Center
Denver, CO
[email protected]

[pyrodork]

i know i'm posting on an old thread, but i just threw a diode in mine. what i'm wondering about is the paper insulation all over. mine was brittle and some did break away before and after the conversion.

the riveted bracket (the wire solder side) actually came off. i believe it was just the paper insulation holding it on, but i'm not positive. i was able to set it back into the remainder of the rivet holes, but i don't want it to short out after i install it.

also, the paper insulation underneath the cutout assembly. much of that was gone when i first took the cutout off to examine it.

i realize i can probably make something myself to replace these, but is there a recommended material? what points must i make sure to have insulated from the body? does anybody sell these things in a kit?

[Tom Wesenberg]

I bought some small pieces of insulating board at ABC Electronics in Mpls, but it's a hit and miss thing. They didn't have any more the last few times I was in the store.

[tbirdtbird]

This may help
from www.mcmaster.com
Ultra-Thin Flexible Paper Insulation

• Temperature Range: -4° to 266° F
• Heat Flow Rate (K-Factor):
  0.003" Thick: 0.15 @ 356° F
  0.015" Thick: 0.25 @ 356° F
• Density:
  0.003" Thick: 87 lbs./cu. ft.
  0.015" Thick: 93 lbs./cu. ft.
• Color: Off-white

Often used in high-humidity applications for its low-moisture absorption, this inorganic-material-based paper meets UL 94V0 5VA for flame retardance and can be used as a flame barrier.

Thick.Wd.Lg. Each0.003"36"24"9583T21$6.980.015"36"24"9583T2227.00










http://www.mcmaster.com/?m=true#elec...lation/=m7n5cd

[pyrodork]

i just got the new bratton's catalog and saw that their diode comes with a kit that includes these gaskets, screws, etc. i'll do some checking around and report back.

[kwisor]

hello
not sure if related but when i start my car the amp meter show no charging untill i start to drive then it will show charging if i incress the rpms it will not show charge till after i start to drive is the cut out sticking till i drive it
kevin

[pyrodork]

Originally Posted by pyrodork

i just got the new bratton's catalog and saw that their diode comes with a kit that includes these gaskets, screws, etc. i'll do some checking around and report back.

little dearborn doesn't sell any internal cutout parts. brattons only has the kit, which is $7.

would gasket material do the same job? or rubber from an old inner tube?

[pyrodork]

Originally Posted by kwisor

hello
not sure if related but when i start my car the amp meter show no charging untill i start to drive then it will show charging if i incress the rpms it will not show charge till after i start to drive is the cut out sticking till i drive it
kevin

i haven't been able to drive my AA yet, but i'm going to assume that's normal. with the higher rpm's, the generator will be spinning faster and generating more power; thus charging the system.

i think the meters on modern vehicles have a wider range, and alternators are designed to work differently from generators. i'll bet that's partially why there's more significant electrical values in alternator cars versus generator cars.

[Jeff/Illinois]

Tom, is it possible to resurrect your pictures on this subject?? Evidently they have been blocked I wished to learn a bit more about fixing an original cutout.

Thank you.

[Tom Wesenberg]

Originally Posted by Jeff/Illinois

Tom, is it possible to resurrect your pictures on this subject?? Evidently they have been blocked I wished to learn a bit more about fixing an original cutout.

Thank you.

Maybe it could be a winter project. That's a lot of pictures lost because of photosuck.

[1955cj5]

The pictures are still on photobucket...

It may take a while to find what you want though!

http://s118.photobucket.com/user/Tom...?sort=3&page=1

[Tom Wesenberg]

Originally Posted by 1955cj5

The pictures are still on photobucket...

It may take a while to find what you want though!

http://s118.photobucket.com/user/Tom...?sort=3&page=1

Wow, you're good. I haven't been able to get into photosuck for about 5 years.
Now, with there being 1400 pictures, is there an easy way for me to put them all on a card? Thanks

[1955cj5]

I wish I knew Tom.....I just googled your name with the word photobucket and there they were.....I really don't know if you can retrieve pictures from photobucket........

Lots of neat pictures by the way!