Generator Rebuild

All I can think of is to get the screws even tighter, or try swapping sides with the shoes. I assume the inside of the case and the shoes were sandblast clean. The air gap is very small, so it only takes a spec of rust or dirt to make it tight.
 
The problem has been solved! I had installed that slip of paper that goes under the wire that connects the two field coils togethe a bit too high. I took it back to the shop where I had the pole screws tightened and after scratching our heads for a while, the shop owner noticed I had placed it just a little too high and some of it was under the pole shoe. He moved it down and now all is good! Thank you for your help!
 
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