I bought a TH starter last fall at a swap meet; "like new" condition. Worked great all this season until it suddenly died. I took it apart and found one brush was completely gone.

So I figured, TH or Hobbicco must sell these right?....wrong. I could not find replacement brushes anywhere.

Next I came to RCU and read. One person suggested getting Dremel brushes. I went to Lowes and they only had one type. They were about the right size but did not have the wires embedded in them. I was worried that using the springs to conduct the electricity would no be good enough.

I went online and could not find any the right size (3/16" x 3/16" x 5/16") I was not sure of the length because the other one might have been worn down too. Anyway, I did find a 3/16 x 1/4 x 9/16. They were 10 for $5 with free shipping from HK from an EBAY [link=http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=320589287151&ssPageNam e=ADME:L:OU:US:1123]seller[/link]. I figured it was worth a shot with paypal payment to mystery dude in HK.

They arrived 2 weeks later and I installed.

Photo 1 and 2 shows what I started with.
Photo 3 shows the replacements.

I cut the plate off and removed the spring. I used a Dremel with a medium grit drum to machine down the brush.

Photo 4 shows after I took 1/32" off each side to make them 3/16 x 3/16

I was surprised how soft the brushes were. Note the originals were carbon-copper but these new ones are just carbon. I hope I can at least get 1 season out of them.

Photo 5 is them installed. Note I removed the old wires and reused the attachment loop but added a touch of solder to hold it. I had the wire coming out of the springs about half-way (because the new ones had the wire on the back versus on top).

Of course, the real trouble is getting the brushes pushed back and the housing back on. I do not know a good way to do this. This time, I made a "J" hook from thin wire and used it to hold back the brushes and stuffed the motor back down; then removed the wires. It did not work the first time and I ended up gouging the top of the brushes as the motor must have been sitting on top of the brushes. I tried a second time and seemed to get it.

Anyone have a better way to install brushes?

Anyway, thought this might help anyone else with this issue. (good old RCU search)