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Thread: Saved Another One From The Scrapman!

  1. #51
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    Re: Saved Another One From The Scrapman!

    Been out of town for a couple weeks except a day home last Sunday but I promised better shots of the bearing erosion so I grabbed a few better ones while continuing the cleaning duties today and here they are. All top halves are to the right.

    Center. I'd guess erosion is upwards of .010" deep at worse points.
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    Rear.
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    Front.
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    More clean-up shots to follow.
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  2. #52
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    Re: Saved Another One From The Scrapman!

    I got all the brush holder parts cleaned up (sand blasted) today and although no shots yet the engine front cover, oil pan, fan and governor housing all got the same treatment.

    Some before, during and after shots of the cleaning. Holder bars and spring mounts all got the wire wheel following sand blasting for the final cleaning.
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    Assemblies will get a coat of clear on all surfaces that don't come in contact with the brushes or their lead eyelet ends to help ward off a future repeat of the "before" condition.
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    And speaking of governor housing, I'm planning a Pierce governor rebuild thread in the near future once I get the new parts so I can show shots of it in all stages.

    I didn't take any shots of the alternator rebuild a couple weeks ago either that included a complete tear-down, sand blasted housings, cleaned slip rings, new bearings and new brushes. I've also got the starter all pulled down for a total cleaning and brush and bushings replacement for it as well. But for now this is it for an update.


    Thanks for looking.
    Last edited by duaneb55; 04-30-2012 at 12:09 AM.
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  3. #53
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    Re: Saved Another One From The Scrapman!

    Quality work for sure Duane!! This build is helping more than you know! Thanks so much.

  4. #54
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    Re: Saved Another One From The Scrapman!

    Well the last three weekends had been spent in San Antonio with the kids and grandkids so not much progress as of late but somewhere along the way I managed to get the starter rebuild done.

    Don't know why I didn't show it but the worst brush is on the side that you can't see. It had worn to the point the non-metalic brush holder was almost contacting the armature commutator.
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    Just couldn't seem to get to the local alternator/starter shop during business hours so I went ahead and ordered the 10MT "tune up" kit on line that included the new bushings and shifter fork I needed in addition to brushes. The new field strap insulator was an nice touch too.
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    Drive housing and end cover blasted with new bushings positioned for and pressed in.
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    Stand by for the next post . . .
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  5. #55
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    Re: Saved Another One From The Scrapman!

    . . . showing the new brushes and holders installed after cleaning and blasting the main housing taking care not to hit anything inside with media. I didn't take any shots of the cleaned up armature so you'll have to take my word it was done.
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    All back together, tested and ready for painting. The solenoid had been recently replaced so I just pulled it down to make sure the contact plate and contacts were good and to clean up all the stud threads, nuts and washers before reassembling.
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    Thanks for looking.
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  6. #56
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    Re: Saved Another One From The Scrapman!

    Just like new Duane! Have you made any progress on the governor rebuild?
    I may try my hand at rebuilding my starter. Is the kit from an auto parts store?
    Thanks again for a great thread.

  7. #57
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    Re: Saved Another One From The Scrapman!

    With respect to the octagon generators....Interesting that the aluminum shunts "ohmed out" OK after sitting for that length of time. So far I only get about 1 in 4 "junk yard saves" that still have a complete circuit through the shunts. Electrolysis failure at all of the steel "crimp" connectors where aluminum and copper connect.

    Anyone installed the copper coils from Fowler (Louisiana)? Comments?
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    Lincoln SA200's... at least 15 - 20. They come and go. Growing partial to the "Short Hoods" in my old age. Last count on Short Hoods was 13 in possession.

  8. #58
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    Re: Saved Another One From The Scrapman!

    Quote Originally Posted by kuzineddie View Post
    Is the kit from an auto parts store?
    All the local auto parts stores - including the Delco "distributor" - don't carry the required individual parts. Nobody repairs/rebuilds anything anymore so all they carry are new and exchange components.


    We do have an alternator/starter shop in town and I planned on getting the parts from them but as I said, I couldn't get there during business hours so I ordered the kit on line so it would be here when I got back home from being out of town.

    Got it from US Auto Electric http://www.usautoelectric.com/ but I will say I'll make the extra effort to get them from the local shop next time.


    Quote Originally Posted by kuzineddie View Post
    Have you made any progress on the governor rebuild?
    As for that, the "rebuild" consisted of a complete tear-down, cleaning and reassembly with a new control shaft seal. All bearings were fine and completely serviceable on this one.

    And there's a reason the regular sources get what they do for rebuilt units as a number of the parts required are available in bulk and/or at minimum order amounts. Believe it or not, the two big ones are the seal and expansion plug for the housing on the opposite side of the control shaft. Control shaft and input bearings are more readily availabe as "off the shelf" parts but the riser thrust bearing is another matter.

    That said, I'll put together the thread soon.
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  9. #59
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    Re: Saved Another One From The Scrapman!

    Quote Originally Posted by hobohilton View Post
    With respect to the octagon generators....Interesting that the aluminum shunts "ohmed out" OK after sitting for that length of time. So far I only get about 1 in 4 "junk yard saves" that still have a complete circuit through the shunts. Electrolysis failure at all of the steel "crimp" connectors where aluminum and copper connect.

    Anyone installed the copper coils from Fowler (Louisiana)? Comments?
    I have them in my machine and they work great.
    1973 Lincoln SA 200, Already replaced shunt coils, Idle board (SOLD)
    1984 Miller Dialarc 250HF, Miller water cooler, 250 AMP water cooled torch, you know the worx.

  10. #60
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    Re: Saved Another One From The Scrapman!

    Hey Duane, you mentioned a post on rebuilding a governor. Did you get around to that, just curious
    1960 Redface SA-200 F 162
    1973 Black face SA-200 F 163 with 5" chop
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  11. #61
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    Re: Saved Another One From The Scrapman!

    Yes I did but just haven't managed to put the promised tread together yet.
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  12. #62
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    Re: Saved Another One From The Scrapman!

    That will work, thanks
    1960 Redface SA-200 F 162
    1973 Black face SA-200 F 163 with 5" chop
    2013 Miller Trailblazer 275
    2013 GMC 3500 welding car

  13. #63
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    Re: Saved Another One From The Scrapman!

    I have been gone awhile, so what's the latest on this project Duane?
    Is it ready for me to pick up yet?
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  14. #64
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    Re: Saved Another One From The Scrapman!

    Naw Mike. It's still in pieces as there have been too many interuptions so if you pick it up you get to put it back together too. I do intend to get back on it soon though.

    I trust you dodged the bullet from Isaac and all is well.
    Last edited by duaneb55; 08-31-2012 at 08:32 PM.
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  15. #65
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    Re: Saved Another One From The Scrapman!

    Quote Originally Posted by duaneb55 View Post
    Naw Mike. It's still in pieces as there have been too many interuptions so if you pick it up you get to put it back together too. I do intend to get back on it soon though.

    I trust you dodged the bullet from Isaac and all is well.
    I think I'll have to pass on the project Duane, too much to do on this end also.

    Yeah, we got lucky on the storm. Lot of wind and some rain in my area. No damage to really speak of except for the usual small limbs and branches except for one tree that uprooted and one that snapped about 5' up from the base. They were expected to go since they were in the unhealthy/dying phase. Neither presented a hazzard to home or sheds so no problem. Hope all is well on your end and every one is fine. Roughneck still doing good and loving it.
    A few of my toys !
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  16. #66
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    Re: Saved Another One From The Scrapman!

    Good save Duane

  17. #67
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    Re: Saved Another One From The Scrapman!

    Well a number of other projects, duties and a little bout with West Nile have kept me from making much progress on the unit but I have managed to tidy up some of the main generator wiring a little over time.

    At least one of the shunt coils has been replaced and under the usual cloth type electrical tape was the typical crimp butt splice that can be a problem somewhere down the road.
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    Forgot to snap a shot of it but under the first section of heatshrink tube is the crimped AND soldered uninsulated butt splice . . .
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    . . . and double sealed by a second section of heatshrink tube.
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    Again, no before photos but if you've been around many SA200s you know the output and brush leads are usually - at the least - cracked and exposing the cable conductors. Some units may even have chunks of original insulation in which case the best solution is replacing the entire section of cablewhich is a much more involved process. In the case of this unit, the cable insulation was (is) only cracked in several places so a thorough cleaning and covering of heatshrink tube does the trick to keep everything together as others have done in the process of refurbing a unit to prevent a possible short.
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    Stand by for the next post . . .
    Last edited by duaneb55; 10-04-2012 at 11:33 PM.
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  18. #68
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    Re: Saved Another One From The Scrapman!

    . . . showing the making of a replacement housing insulator/cable guide. It's not unusual for the insulator/guide to be at least broken (like this one) if not missing altogether.

    Thought of using a thick piece of leather but opted for a piece of laminated cardboard corner guard used for shipping banding. The original drive rivets were driven out from the inside, holes drilled to the proper tap drill size and tapped for 10-24 fasteners. I'll let the photos tell this part of the story.
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    Yes, the small gauge red and black leads are stilll missing and won't show up until the unit is reassembled.
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    Thanks for looking.
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  19. #69
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    Re: Saved Another One From The Scrapman!

    Duane, looks great. I received the parts yesterday. Today I'll be priming and painting the chassis and trailer in preparation of reinstalling the engine. I rebuilt the carb while awaiting the parts. Thanks again.

    Tim Pierce

  20. #70
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    Re: Saved Another One From The Scrapman!

    Nothing spectacular and done quite some time ago but I forgot to post a couple photos of it - new battery box door.

    New door with finger and handcrank cutouts to match original. Battery holddown bolt holes not yet drilled.
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    Original handcrank opening backer in place on the new door.
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    Door retaining bolt nut tacked to inside of new battery box (rather than attempting to salvage original weldnuts).
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    Thanks for looking.
    Last edited by duaneb55; 10-20-2012 at 05:26 PM.
    MM200 w/Spoolmatic 1
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  21. #71
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    Re: Saved Another One From The Scrapman!

    Finally got around to checking out the idler control board for the old girl and found it to be inoperative. Traced the problem to a shorted flyback diode (yellow arrow).

    I use Brake-Kleen to remove the protective coating off most boards prior to making a repair but the protective coating on Lincoln boards is extra tuff stuff and impervious to Brake-Kleen but a short soak in acetone proved to help break the bond between the coating and board.

    However, it also broke the bond between some other things as well such as the insulation coating on the 1/2ohm, 5W resistor and somewhat attacked the housing of the 50uF, 16V capacitor (red arrows). Even though the the board still functioned with the affected resistor and capacitor following the replacement of the diode, they still got replaced to avoid a potential failure down the road.
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    So, what started out as a $.03 repair (you read it right - $.03) wound up being a disapponting $1.12-1/2 repair (the 1/2 cent is because the two pack of resistors cost $.95).



    Thanks for looking.
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  22. #72
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    Re: Saved Another One From The Scrapman!

    Quote Originally Posted by duaneb55 View Post
    So, what started out as a $.03 repair (you read it right - $.03) wound up being a disapponting $1.12-1/2 repair (the 1/2 cent is because the two pack of resistors cost $.95).
    Well there goes the budget! With added charges like this it's easy to see why guys want so much money for these machines when they are rebuilt.


    Nice work as always there Duane.
    .



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  23. #73
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    Re: Saved Another One From The Scrapman!

    It's been over a year and I STILL don't have this thing done! Sheeesh!

    Just finished up rebuilding another one for a repeat customer that included changing the shunt coils and a host of other items and I figured I'd take advantage of the momentum and take care of a few sheet metal items that needed attention on mine. Got 15 photos to share so there will be 3 posts coming up.

    First up is the filler/support ring for the main brushes cover. Local fab shop couldn't roll the flange on the ring so it was accomplished as a 2-piece job.

    Main "ring" cut to ID/OD and 3/8" wide strip rolled to approximate OD. Notches for the fasteners that hold it to the exciter housing were match to those of the sample piece from the shunt unit.
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    Band tacked in place with the MM200 and everything cleaned up ready for TIGing with the 180 SD.
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    Boy do I need a lot of TIG practice!
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    From the back side . . .
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    . . . and the front side all cleaned up with the softpad to have an original piece rolled appearance.
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    On to the next post . . .
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  24. #74
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    Re: Saved Another One From The Scrapman!

    . . . with the filler ring mounted to the exciter housing.
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    20ga(?) piece of galvanized drilled for plug welding to the "L" clips to make the main brush cover.
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    Cover in place.
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    And on to the last one . . .
    MM200 w/Spoolmatic 1
    Syncrowave 180SD
    Bobcat 225G Plus - LP/NG
    MUTT Suitcase Wirefeeder
    WC-1S/Spoolmatic 1
    HF-251D-1
    PakMaster 100XL
    '68 Red Face Code #6633 project
    Star Jet 21-110

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  25. #75
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    Re: Saved Another One From The Scrapman!

    . . . to address the exciter brushes cover that was full of rust holes usually found in same.

    Cut piece down to 2-1/2" from mounting surface with the 3" cutoff wheel . . .
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    . . . then sandblasted to prep for welding . . .
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    . . . where I'll repeat I need a lot more practice but it too cleaned up nicely with the soft pad.
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    All fitted up and in place. A flat washer was TIGed on and trimmed to shape to form a new lower hole (no pic).
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    And a final shot showing total clearance between it and the armature shaft.
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    Thanks for looking.
    MM200 w/Spoolmatic 1
    Syncrowave 180SD
    Bobcat 225G Plus - LP/NG
    MUTT Suitcase Wirefeeder
    WC-1S/Spoolmatic 1
    HF-251D-1
    PakMaster 100XL
    '68 Red Face Code #6633 project
    Star Jet 21-110

    Save Second Base!

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