pic: burnt up TETRIX motor

[chapman1]

In order to resore our blown Tetrix motor for "development" use (working on them is an "illegal" mod), I took it apart as follows:

- remove from gearcase
- mark the orientation of the brush plate relative to the case
-file away the areas where the case is "lipped over" to hold the brush plate. I used a small triangular file.
- carefully tap the opposite end (the gear) on a hard surface to pop the brush plate up.
- do not pull up on the brush plate! This will damage the brushes. Instead, slide it sideways off the commutator.

Once I had it apart, I could see that the inductor was obviously smoked. I unsoldered it, and in its place, soldered a solid wire (don't worry, it will still work!)

To reassemble:

- create 2 loops using fine thread. Hook one loop around each of the brushes.
- with the loops, carefully pull the brushes far enough apart to clear the commutator.
- pinch the threads around the circumference in a way that will hold the brushes while you reinstall the brush plate on the shaft.
- when it's in place, snip each thread loop and pull one end to remove them.
- place the motor on its side and using a small hammer, gently "tab over" the housing adjacent to the notches you filed away to remove the brush plate.

If you are as lucky as me, the motor will run like new! Granted, it doesn't have the "inductor", but it seems to work just fine for testing and development. It pains me to have to spend $30 each time a motor blows!