Power House Generator Question

[BAAP]

The judging standards talks about three different styles of Power House generators. The two earlier versions had 5 brushes and the one later version had only 3 brushes. I've been asked to look into having the black bakelite brush holder plates made. I've talked to one of my sources and he said that it would be no problem making it. Before we spend a bunch of time on this project we have a question about the earlier 5 brush holder plate. Was the only difference in the 2 earlier versions the location of the cutout? Basically I'm trying to figure out if there were only 2 different brush holder plates (1 for the 5 brush generator and 1 for the 3 brush generator) or 3 different brush holder plates ( 2 for the 5 brush generator and 1 for the 3 brush generator). I'll be contacting the archives for the prints but I just want to make sure I get all that i need.

Also, does anybody see a problem with this plate being a different color than black? We will be making it out of a high temperature plastic, and the only sources we have found are not black. I figure this is an internal part so color really should not matter as long as the brush holders, and mounting arm parts fit and all of the slots and holes are in the correct spots.

Any thoughts or comments before we begin on this?

Thanks

Jeff

[Jim Mason]

The differences are all external, the brush holders are interchangeable and will never be judged for number of brushes or color.

20191011_093819.jpg
20191011_093800.jpg

[tbirdtbird]

Jim is an extraordinarily reliable source of info.
And thanks Jeff for supporting the hobby the way you do!

[Tom Wesenberg]

Will the new brush holder include all the metal parts in place, or do you plan on only making the Bakelite part and have the customer remove and install the metal parts?
If all the metal parts are included, then I can see several sales coming.

[BAAP]

Will the new brush holder include all the metal parts in place, or do you plan on only making the Bakelite part and have the customer remove and install the metal parts?
If all the metal parts are included, then I can see several sales coming.

These are going to be just the bakelite part, but it will be drilled for mounting all of the brackets and hardware to it. I just don't see enough of a market in this to invest in the stamping tooling for those parts. As it is right now this plate looks like it is going to be approx $40 - $45

[Rowdy]

That poses another problem. Attaching the metal parts without cracking the bakelight. I already have one with a rivit missing and no way to attach without braking it. Rod

[DaWizard]

This also brings up another question. Will the proper rivets and rivet tool be included in the price?

[tbirdtbird]

That poses another problem. Attaching the metal parts without cracking the bakelight. I already have one with a rivet missing and no way to attach without braking it. Rod

Rod, I have never worked on a powerhouse. Could a 10-32 or 8-32 panhead screw and nylock be used instead (do not know if there is enough clearance).
Your issue is a huge reality of a problem.

I just bought some window crank knobs for the Stude project we are working on and they needed to be peened over to attach them. I queried guy making them and he said the plastic would take the slight pounding required, he said the metal stem was not that hard. I put a micro-fiber over the backing plate and gingerly did the peening, expecting everything to go all to hell, but he was right, it worked fine.

Maybe Jeff could comment on this, since his part will be plastic and not bakelite, which cracks just by looking at it

[ClintonR]

Are these plastic plates still available? I am looking for a 3 brush plate. Thanks

[Rowdy]

Are these plastic plates still available? I am looking for a 3 brush plate. Thanks

I have not seen them offered for sale yet. Maybe I missed them. Rod

[BAAP]

Due to lack of interest these were never made.

[ClintonR]

Thanks, that is a real shame but I completely understand.

[1930 Closed Cab PU]

Not knowing what I am talking about, any chance they could be 3D printed out of some equivalent material?

[rheacox]

Not knowing what I am talking about, any chance they could be 3D printed out of some equivalent material?

I think 3D printing could work out well. SLA would probably be the best way to go for finish and strength. It's a pretty easy shape to model/print.

[Rowdy]

I think 3D printing could work out well. SLA would probably be the best way to go for finish and strength. It's a pretty easy shape to model/print.

The real question is which resin would work best. I have seen a few of these in action and the selection of resins is abit overwhelming. I would think ABS to be a poor choice as it breaks down too quickly in heat. But then again none may stand up as long as bakelite has. But bakelite is more brittle than most modern plastics. There has to be a good middle ground. Rod

[rheacox]

The real question is which resin would work best. I have seen a few of these in action and the selection of resins is abit overwhelming. I would think ABS to be a poor choice as it breaks down too quickly in heat. But then again none may stand up as long as bakelite has. But bakelite is more brittle than most modern plastics. There has to be a good middle ground. Rod

Agreed. There are ceramic reinforced resins that might work well. I think they're more heat resistant than ABS and tougher too. Might be as brittle as bakelite though.

[ClintonR]

I am enjoying this conversation. Do you think this might become a real possibility? I for one would like to purchase one of the three brush plates.

[Steve Plucker]

Clinton,

You just might have to bite the bullet and find an original "doner" generator with one in it.

Pluck

[ClintonR]

I guess your correct Steve, I have been looking but I think I will find hens teeth before a 3 brush plate

[Badpuppy]

FWIW bakelite can be glued, epoxy I think, if you have all the pieces.

[ClintonR]

Hello Badpuppy, I don't quite have all the pieces, I am missing about an inch to make the complete circle. I think I will try gluing the pieces I do have together and then maybe I can figure out a way to complete the circle. Worth a try.

[Mitch]

There’s gotta be a bunch of powerhouse genny’s or genny parts laying around in someone’s barn. But where

[alexiskai]

Doug Black here in NC has several restored powerhouse generators. He might have parts.