Tool Electric tool motors that require carbon brushes

[Elektrishun]

Every so often I take inventory of some of my older tools that have integrated electric motors which use carbon brushes. I check to see how much carbon is left and decide if I need to get ready for replacements or maybe just get them to have on hand.

Depending on the age of the tool I know it can be difficult at times to source new brushes. I tried to source brushes for a much older tool a few years back (I believe it was a Stanley fixed based router???). After coming to a dead end I contacted a company in Calgary that specialized in carbon brushes. During a long conversation about the carbon brush business he told me the writing was on the wall. With more machines/tools switching to VFD controlled AC motors and brushless DC motors it was hurting his business. Nonetheless, based on the info I gave him, he sent me brushes with a similar profile to try and adapt to the tool.

Some old tools, especially corded tools, can be replaced for relatively cheap compared to their battery equivalents. Other older tools that have similar modern replacements can still be quite expensive and I am always concerned about the quality difference.

Anyone concerned about some of their "good old" tools becoming obsolete do to something as simple as unobtainium carbon brushes?

 

[ChazzC]

Not too concerned: if you can’t find the “correct” brushes you get ones that are close to the cross section and:

• Figure out how long the correct brush should be (maybe check when new or at least now)

• File the end of the original brush square & smooth

• Trim the end of a new brush so that when combined with the filed original brush it will be the right length

• File the end of the trimmed new brush square & smooth

• Insert the new brush in the motor, followed by the old brush (with the attached pigtail) and install the cap

This setup may arc a little, but if the joined surfaces are smooth and square it should be minimal.

Alternatively, for a while replacement brushed universal motors will still be available. You can also keep your eye out for “junk” motors to use as brush donors.

 

[Dan Dubeau]

That's much more proactive than I am. I usually wait until the smoke starts pouring out to think about replacing the brushes lol. I have had to modify brushes to fit before, so there's still always that possibility if factory replacements can't be found. I've fully bought into the brushless battery hype though. It's rare that I reach for a corded tool anymore, having replaced most with battery versions, and now swapping those out for brushless when I come across deals. The exception being my worm drive saw, because I don't feel like shelling out for an expensive battery version that can do the same work that it can. My old 18v makita recip saw is dying, and I've been trying to find a brushless replacement for a while now. I have a good Bosch corded version, but can't remember the last time I had it out of the case. Years.

Corded tools still have their place, but they don't really fit my needs anymore. I have about 6-7 angle grinders, corded, but 95% of the time will be using either of my cordless ones unless I'm doing a big project outside, or a lot of millscale removal.

 

[djberta]

One of the reasons I have the one series of dewalt angle grinder is the brushes are really good. I have had them almost on fire, smoking like crazy and its a 5 minute job to replace the brushes. I still find it kind of cool that a lot of the asian made stuff comes with replacement brushes. Like most on here I have switched to cordless for almost all of my needs. Aside from the half inch drills and grinders for welding that is.

 

[ChazzC]

That's much more proactive than I am. I usually wait until the smoke starts pouring out to think about replacing the brushes lol.

Thinking about it, I guess I’m proactive, too: I’ve had spare brushes for my vintage Dremel MotoTool for decades, and when picked up another (even older) one bundled with a Dremel Drill Press Stand which is what I wanted, I got some more.

 

[140mower]

This was more by fluke than good planning, but ya, I gave having a few on hand might come in handy one day.
..... I swear, I am not really a "sky is falling" kinda guy, but I can see how one might think so...

 

[Dan Dubeau]

I need to find a brushless drill either in Makita, or Miwaukee 18v. I've already replaced the brushes in my Makita once a few years ago, and suspect they are getting close again. Now I know who to bug for another set.......

 

[phaxtris]

Most of my brushed tools are Makita, no problem getting brushes, about 7 bucks a set from Makita. I did have to change a set on a Bosch tool recently, i was shocked, i think it was 20+$ for the set, but in any case still available

 

[Elektrishun]

View attachment 59526View attachment 59527
This was more by fluke than good planning, but ya, I gave having a few on hand might come in handy one day.
..... I swear, I am not really a "sky is falling" kinda guy, but I can see how one might think so...

Okay... So I followed the instructions "Use the attached reference chart to find your tools replacement brushes". Now what? Are you going to post a phone number to call? What is the ETA and warranty? What kinda reviews are you getting? Do you accept 3rd party cheques?