How to Rewind an Electric Motor

from wikiHow - The How to Manual That You Can Edit
Electric motors are relatively simple mechanical devices, but rewinding the coils on a DC motor is a precise task that should only be undertaken by those who with experience in mechanical or electrical repair. A mistake or poorly-performed rewind job will result in a motor that doesn’t work. At that point, your only options are to buy a new motor or to take it to a professional shop for repair. Given the variety of motors and types of windings, this can only be a general article on rewinding. If you don’t understand the terminology, you shouldn’t be rewinding a motor; once you start removing the original coils, there’s no going back.

Steps

Clean your work surface to make sure it’s free of dirt and dust.
Remove the motor housing to reveal the windings.
Document the present configuration by taking notes or photographs. You may even wish to videotape your deconstruction so that you can precisely recreate the original winding pattern and connections.
Take the wire from the tabs on the brush pads. Bend the tabs gently (and as little as possible) and completely remove the wire from the tabs before cutting the coils of the wind.
Cut the coils in the wind free from the motor. The easiest place to cut is at the tops of the coils at the top of the armature. Count the number of winds in each coil so that you can rebuild the motor to its original configuration.
Check the insulation revealed before you rewind an electric motor. If it’s in good shape, you can put it back in place before beginning your rewind. You can replace burned or damaged insulation with similar material or insulating tape.