Perry Ruiter’s Generator Rebuild and 2-Brush Conversion ~ Driving Classic

The Harley-Davidson V-series engines started utilizing the Mannequin 32E 3-brush mills in 1932.  I assumed that I’d be utilizing a rebuilt 32E for my construct and went about searching for a good builder who hopefully might provide me with a totally rebuilt unit as I didn’t have a core to rebuild from.  After a bit looking I discovered about Perry Ruiter who rebuilds 32E mills up in Canada.  I despatched him a quick electronic mail telling him what I wanted and what I needed to do with the motorbike and he rapidly beneficial that I’m going with one in all his rebuilt 32E’s that had been transformed to a 2-brush mannequin.  Perry went the additional mile and never solely educated me on the distinction between the 3-brush and 2-brush set ups, but in addition took photos of the complete rebuild course of explaining every step.

So why convert a superbly good 3-brush generator to a 2-brush? As you’ll be able to see from the chart beneath, a 2-brush generator begins to cost earlier, will get as much as most output quicker and the output does not drop off as velocity will increase. Not evident from the chart, one of many important benefits of a 2-brush conversion is that the generator’s output is all the time matched to the demand. If the battery wants a little bit of a cost, output will increase till it’s charged then drops down. While you flip the lights on, output will increase, while you flip them off, output drops down. With a 3-brush generator the place of the third brush determines the cost price and also you’re caught with what you have set it to.

The opposite important benefit to a 2-brush conversion is you’ll be able to run a sealed battery. It’s essential to use a moist battery in a 3-brush system. In a 3-brush system, the battery is accountable for voltage “regulation” (reminiscent of it’s, the previous bulbs are rated 6-8 volts since voltage bounced everywhere). A contemporary sealed battery wants a nicely regulated cost price. That is offered by a contemporary stable state regulator. You may get away with a sealed battery in a 3-brush system if all you do is run the grand youngsters across the block as soon as a month, however hop on the bike and run at highways speeds for a day and you will have destroyed the battery. It isn’t unusual for them to truly explode on this state of affairs. They only cannot take a cost from a 3-brush system.

Now let’s take a look at the steps Perry takes to rebuild a 32E and convert it to a 2-brush system.

The generator meeting begins with the commutator finish casting and brush holders. Colony’s terminal equipment is used together with their generator body screws.  Perry swaps out the star washers for parkerized ones and makes use of customized made brush holder insulating papers that are appropriate. Contemporary cadmium plating, parkerizing and glass beading guarantee the suitable finishes. New fillister head screws, a top quality sealed Japanese bearing and a NOS bearing defend washer spherical issues out.

As soon as the comb holders are put in, Perry checks to make sure the detrimental brush holder is grounded and that each terminals are remoted from one another and from the tip casting, however nonetheless have correct continuity with their respective brush holder and terminal.  Be aware that the multimeter is set to ohms for checking continuity/resistance.

The finished commutator finish casting meeting is put aside till wanted for remaining meeting.

Right here is the generator physique with discipline coils and pole sneakers. Since we're changing the generator to  2-brush, these discipline coils are from a 58-64 Panhead generator provided by Jap Motorbike Elements. You can too convert to 2-brush with the inventory 32E discipline coils by altering how they're linked. See Harley Service Bulletin 418 for extra particulars. Pole shoe screws provided by Colony.  Once more high quality sealed Japanese bearing on the drive finish too. Astute readers will notice it is a later generator physique that takes the neoprene seal.  This type physique got here into use over the past couple years of Knucklehead manufacturing and continued on with the Panhead. It ends in a pleasant little improve that's invisible when put in.

For the reason that discipline coils had been initially supposed for a later generator, Perry modified the terminals and prolonged one lead previous to their set up within the 32E physique.

Perry snugs up the pole sneakers utilizing a Snap On influence driver with a customized formed screwdriver tip from Brownells. This lets him get the pole screws lifeless tight with out injury to the screw heads.

Now the generator is prepared for remaining meeting.  The gear, spring and oil deflector are provided by Jap Motorbike Elements.  The brand new brushes and replica armature come from Dixie Distributing. Perry made a batch of the armature bakelite washers to make sure they're the proper dimension.

When putting in the roll pin within the gear, Perry makes use of a customized made bench block to help the armature and to make sure that it's not unintentionally bent when the roll pin is pushed in.  Be aware that the majority replica gears have a 3mm reasonably than a 1/8 inch gap.  To compensate Perry makes use of 3mm roll pins. Perry says "You'll be able to't drive a 1/8 roll pin right into a 3mm gap!".  Within the above photograph, you too can see how Perry parkerizes the generator physique previous to portray.  This helps maintain rust at bay ought to the generator get a scratch or a rock chip.

As soon as the generator is totally assembled a battery is connected to motor it.  The generator ought to motor in a counter-clockwise course when noticed from the gear finish. If it rotates the opposite means you've got your discipline coil leads reversed.  Motoring does two issues, it verifies that the generator is assembled correctly and gives an preliminary polarization for the pole sneakers.  The generator depends on residual magnetism within the pole sneakers for preliminary pleasure every time the engine is began.

Recall we transformed the 32E from being a 3-brush generator to a 2-brush generator. Within the photograph above you'll be able to see that the third brush holder sits empty within the assembled generator.

For the reason that generator has been transformed to 2-brush, a regulator is required. The pure alternative is a stable state Vtronic 6V regulator provided by RetroCycle (additionally accessible in 12V). Sadly the producer solely provides this unit in a 38 to 57 three put up type. Perry has developed a modification of the Vtronic unit to offer it a two put up outward look which is appropriate for the VL sequence. The third put up is hidden on the underside.

Though he has a Solar generator/alternator check bench, Perry has a wierd affection for this historical generator tester rescued from an previous Harley vendor years in the past.  The generator help is a piston pin push software.  Right here the generator is being run at velocity to confirm that it and the regulator are working collectively as they need to.  A Cycleray headlight, simply seen on the decrease left, is periodically hooked as much as present a load and confirm that the regulator and generator reply to the elevated demand after which drop again down when it's eliminated.  All of those assessments are carried out utilizing a multimeter to precisely measure adjustments within the generator's output.  The meter is about to amps for this check.

To complete issues out, Perry added a canopy on the regulator, a pleasant previous authentic tag and a interval aftermarket chrome cowl to finish the generator. The duo is now prepared to supply many miles of trusty service.

Procuring Listing

Colony Machine
30012-32 Generator Screws
2126-12  Terminal Equipment
9520-4 Pole Screws

Jap Motorbike Elements
A-31035-31  Oil Deflector
A-31070-30  Generator Gear
A-31040-31 Spring
E-1007  Subject Coils

0478506  Vtronic 6Volt Regulator

Dixie Distrbuting - 937 322 0033

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