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Carefully and yes the front to back grooves IF the insulation in them is at or above the level of the Copper. Its normal for the surface the brushes ride on to wear lower than the rest of the commutator, this quicly wears the corners off the new brushes to seat them in then they wear normally. Basically you dont want anything on the commutator that is rough, or will dig into the brushes... if there is eather the generator has shorted and run hot or someone has done a hackers job and undercutting the commutator. If you send me the armature your not using I can run it up on the lathe at work and see if I can clean the commutator up... Glad you made it home anyway... and dont forget to plug those oil access holes. Keith > Keith, you mentioned undercutting with an xacto knife. How exactly do you do > that? Is that for cleaning out the front-to-back grooves? Do those need to > be cleaned out? ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ List info at http://www.vwtype3.org/list | mailto:gregm@vwtype3.org