Replacement generator terminal wire is way too stiff

[Sparky]

I'm talking about the internal wire from the generator output brush to the terminal stud. The cloth insulation on my original wire was falling off and I was afraid of a short , so I ordered a new replacement. The gauge is correct, but the plastic insulation is way too rigid, so much so that it overcomes the spring in the brush holder and will adversely affect the brush force. So now I'm thinking of applying liquid tape to the original and putting it back. Will this hold up? Any other suggestions?

 

[Kurt in NJ]

I used to take apart a shoelace and use the outer covering, wrap some thread around each end with a dab of glue to prevent unraveling ---then I bought soft sdpagetti insulation from a electric motor repair shop----it's hard to find the proper wire with a high strand count and soft insulation

if you don't mind the look of modern wire--
http://www.acerracing.com/ball_bearings/Superworm_Silicone_Wire_16_Gauge_10_feet-1465-75.html

 

[Tom Wesenberg]

Is your output post at the front of the generator 1929-March 1930, or at the rear March 1930-end?
If it's at the rear then a replacement lower distributor plate wire might be long enough. Otherwise do as Kurt said. I've used liquid tape to fix bare spots on that wire, and it works fine.

Hobby shops sell flexible wire.

 

[Mike V. Florida]

Hobby shops sell flexible wire in the RC section for RC car battery packs.

 

[CWPASADENA]

I found some instrument test lead wire at an electronic supply store which is multi-strand and very flexible.

Chris W.

 

[BILL WILLIAMSON]

In a pinch, rip apart a flat 110 Volt extension cord. The wire is multi-strand & usually has soft insulation. I've used it for the internal distributor wire, even. It also makes durable jumper wires & test leads.
Bill W.

 

[Sparky]

I found some instrument test lead wire at an electronic supply store which is multi-strand and very flexible.

Chris W.

Great idea! I was able to find some "extra" test lead wire in our test lab. nice and soft.

 

[katy]

Check the gauge of that test lead wire. You should have at least #16 but preferably #14 for the wire from the brush to the output stud. It's carrying the full generator output current.

 

[Tom Endy]

Bratton's sell a fine flexible generator wire. I believe it is the one you are looking for. Part number 15230. I had a recent conversation with Walt about this wire. It is the same wire used on the lower plate of the distributor. it is made longer to accommodate the generator. If you are going to use it in the distributor you have to shorten the length. Apparently the terminal end is the same for both applications. I have only used them in the distributor.

Tom Endy