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Strain relief for new head wires  Rate Topic 
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 Posted: Wed Jul 10th, 2019 03:25 am
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Justin Tanger
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Joined: Thu Jan 26th, 2012
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Finally getting to redoing a couple stamped Westies I dissembled 8ish years ago now. At the time I welded up a brace and a couple stator puller pieces to separate them using a long bolt. Works great, still a PITA though. Missing a few parts now, hoped to get at least one back together. Started on the older 3 wire fan, soldered and liquid electrical taped  the head wires, but as I rotated to press each side of the stator back into that ridiculously tight housing they were flopping back and forth. After completion I checked them and my liquid e tape had split so went to touch up and a wire came off in my hand, broke right at the coil. Not going to rewind one of these, so scrap, unfortunately. These wires are incredibly fragile, and very thin.

Googling after I see this is a common problem, so here is what I came up with to not go through it again. Cleaned stator area of second fan with electric motor cleaner, soldered carefully without allowing wire to flex much, ran a piece of 3/16" 3:1 heat shrink over each wire (will cover with black shrink later) and clipped to overhead light to prevent any more stress fractures, heated wrap, cooled, and applied epoxy, which also makes a good insulator, to lock my shrink wrap solid to the stator windings. The shrink wrap acts as a strain relief and the weak part of the old wire is immobilized. 3:1 is thicker than 2:1 when cured, BTW. So far so good, pressed back in, resistance seems to check out and stator fits fine, just hoping I can cob together a functional oscillator between these two fan's parts now, as I'm missing the lower cover for this one and need that to keep grease from getting everywhere. Redrilled and tapped to adapt oscillator mech from the other fan. Fingers crossed the worm gear fits.


What do you all do to keep wires from breaking at the stator?






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 Posted: Wed Jul 10th, 2019 01:03 pm
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Darrell Koller
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I do the same thing only I use hot-glue.

---Darrell

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 Posted: Wed Jul 10th, 2019 04:28 pm
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Steve Stephens
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Here is a method for headwire tie down used by our MMM (Meticulous Motor Man Tom Newcity).  This would seem to be closer to an old factory method with no glue to someday have a hard time undoing.  He uses a darning needle to help pull the lacing cord through small gaps in the stator.



Last edited on Wed Jul 10th, 2019 04:29 pm by Steve Stephens

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 Posted: Fri Jul 12th, 2019 04:08 am
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Justin Tanger
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Dang, that is meticulous, looks great! The Westy heads exit the housing right above where they exit the coil and stator only fits one position so don't think it'd work for them but I have my eye on an Emerson locally so will keep it in mind for the future. I couldn't fit the housing trim piece on because the epoxy was set at a slightly wrong angle so wires were in the way.

Got these two fans combined, oscillator works also without modifying the worm gear even, just had to drill and tap the stator housing. Combination of a 516860-A and 315745-A.





running vid -
 

Last edited on Fri Jul 12th, 2019 04:09 am by Justin Tanger

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