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 Posted - August 22 2015 : 8:51:49 PM
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I had a weak running Athearn Trainmaster. Instead of replacing the motor though, I completely rewound it!
https://www.youtube.com/watch?v=TDCpOzql65k
It's not something I do a lot, but sometimes, I can really get some great results from it!
Darth Santa Fe, doing weird and challenging projects for the fun of it!
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 Posted - August 23 2015 : 12:49:17 AM
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| Nice Darth. I'd like to have seen a video of you doing the actual winding. Cool performance results.
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Posted - August 24 2015 : 10:47:31 AM
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| It looks like you had great results! I'm also interested in your method. Did you just wind it by hand or...? Could something like this be done on a Tyco PT?
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Posted - August 24 2015 : 6:37:02 PM
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Nice job! 
Did you use the same gauge wire to rewind?
Carpe Manana!
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Posted - August 25 2015 : 9:40:44 PM
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DaCheez, I did wind it by hand, making sure the wiring and pole arrangement was exactly like it was originally. 120 turns per pole of 34 gauge seems to be the maximum that this armature can hold, because there isn't enough room for anymore!
scsshaggy, the wire was the same gauge as what Athearn used. I think the old black "Jet" motors use 32 gauge, so a rewinding with 34 gauge could make one run slower and more efficient like a more modern motor! That is a lot of work of course, but it would be an interesting experiment.
Darth Santa Fe, doing weird and challenging projects for the fun of it!
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Posted - August 25 2015 : 11:57:42 PM
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| Interesting. How did you deal with the ends of the wire? For some reason I remember the Tyco commutators having small dabs of solder on them (although it's been a while since I've been in one). One day I'll try this, I never knew you could do it by hand. Very cool.
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Posted - August 26 2015 : 12:27:53 AM
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The commutator had little posts on each segment, so I wrapped the wire around those a couple times and moved on to the next pole. If it's just little spots to solder, then you solder the end of the wire and then start winding.
I think the PT armature uses very fine wire, probably close to 40 gauge. You'll want to measure with calipers to be sure. What I might try with that one is to go up one or two gauges (like 39 or 38 if it is 40) and do the same number of windings as before, which will decrease the resistance for more power, but it should still be efficient enough to not get too hot!
Darth Santa Fe, doing weird and challenging projects for the fun of it!
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Posted - August 26 2015 : 10:05:57 AM
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Awesome, thanks! One day I'll try this...
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Posted - September 29 2015 : 03:49:25 AM
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 This is awesome stuff!!!
I have several of those old "Jet" motors. Something like rewinding, was something that never
crossed my mind - but seems like it should have!
My first candidate would have to be one of my BB SW1500 switchers. The motors are weak,
and run POORLY at slow speed - you know, where a switcher SHOULD run!!
Could you please post some pics of the procedure??
Also, what does that do to the amp draw! (I run DCC)
Carmine - CEO, Engineer, and Chief Bottle Washer
Pacific Belt RR, in HO Scale, Since 1975! 
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Posted - May 15 2016 : 01:01:10 AM
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pacbelt, sorry, I don't have any pictures to post. I also show some of the rewinding process in one of my American Flyer restoration videos, so that may help. If you decrease the thickness of the wire and do more turns, the amp draw and speed will decrease while the torque increases (to a point). I think the old jet motors use 32 AWG wire, and although I haven't unwound one of these (yet), I would guess they're around 80 to 90 turns on each pole. If you can change it to 100 to 110 turns on each pole (same number on all poles!) with 34 AWG wire, I believe the performance will be closer to a gold motor.
Darth Santa Fe, doing weird and challenging projects for the fun of it!
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 Posted - May 15 2016 : 01:42:19 AM
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Out of curiosity, have you taken a look at RDC-1's Powertorque Performance Project?
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Posted - May 16 2016 : 12:37:58 PM
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| Excellent work Darth. Do you think this would work for the older dark grey Athearn motors? Or it is better to just replace them with a gold motor?
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Posted - May 17 2016 : 01:37:11 AM
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The old motors use a thicker gauge of wire with fewer turns, so if you replace it with thinner wire and more turns, I think you'll see improved performance.
Darth Santa Fe, doing weird and challenging projects for the fun of it!
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