Resistor Motor Help

[jay nesbitt]

Hi,
I am trying to help my mom with her old three wheel Ezgo Marathon. Got her a set of batteries and cables yesterday and put them in. Was replacing the cables to the motor and had a very difficult connection to remove. After much penetrating oil and time, I got the nut to move....a little .....was trying to be gentle , but ended twisting the stud off. Some master mechanic had put a steel bolt in the motor. So I removed the motor to replace the bolt only to find the field connection was now broken. The field winding appears to be aluminum, to my surprise. Is there a standard repair for this? Suggestions? thanks,
Jay

have never done a repair but have seen they sell the studs with a wire soldered to it
like this

i'm sure one of the pros will chime in

[jay nesbitt]

Well, IF I could solder aluminum to copper, I'd be home free; but I can't. That leaves me with some kind of crimp on splice and that's where I was asking for help. Surely someone has had this problem......

Along the lines you suggested....IF I had an aluminum bolt, I guess I could weld it to the winding lead. (?) (!)........

thanks,
JAy

[jay nesbitt]

oops!

[jay nesbitt]

Well I was hoping there would be a neat kit or someone else who have been through this.; but then again I am dealing with a relic from the past.....

thanks,
Jay

[cgtech]

Find a local starter/alternator/generator, they likely can fix your motor.

[jay nesbitt]

Thanks for the idea! I called a local rebuilder and asked him. He seemed to think that my idea of TIG welding an aluminum bolt onto the winding was best.

thanks,
Jay

[tculpepper]

I had to replace a stud on the field winding. I got a set of new brushes. I replaced them and removed one of the studs from an old one and the broken stud from the field winding. I tig welded the old "new" stud to the winding and put it all back together. No problems so far.

[jay nesbitt]

Sounds like you had copper field windings?

I say that 'cause I've never seen any aluminum on brush studs an any motor I've ever seen. If I had copper winding, I'd just solder a ring terminal on it and put it back together.

The starter guy I talked to said that VW starters (at least some) had aluminum field windings.

thanks,
Jay