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Discussion Starter · #1 ·
Hi

Am in my late 50s and have been a DIYer since my childhood, growing up with a father who was an electrical engineer, who designed the electrical components of power stations working for a big utility company in South Africa, but could fix almost anything around the house.
I helped from a young age with motor mechanics, wood working, metal working, making metal components on a lathe, electronic projects (making amplifiers and radios etc). After he passed on, I converted a VW Beatle into a Baja bug at 19 years old. After marrying and settling in Cape Town, I inherited some of his old power tools. I have a small table saw which during our COVID lock down I have been doing a lot with. I added an extension to it, to which I mounted a router and jig saw. On researching for my table saw I was surprised to find only one result on the internet which matched and was amused to discover that my Tauco/Delta table saw was manufactured pre 1939 :surprise: I think my father acquired it in about the 1950s.

This tool is unbelievable. It is still working perfectly, and during this lock down, I have watched tons of videos on table saw setup an usage and that's were I verified that my idea of adding an extension so I could use my accurate table saw fence with my router, was a common YouTube video post. By the way this table saw is interesting in that the arbor does not tilt or move up or down. Raising the blade height involves winding the lever that lowers the table top itself, and cutting bevels involves tilting the table top. Not the easiest of ways to cut bevels I can tell you.

So all was going well until I finally finished my setup of the extension for jig saw and router, and I was taking some photos to show my older brother what I had done with the saw he knew so well. I mounted the jig saw and router, temporarily, under the table and took photos. Later I wanted to use the router but when I turned it on it immediately fell to the concrete floor. :crying: I had forgotten to tighten the clamp when I mounted it just for the photos. It is one of those routers which you rotate in the base to raise or lower it. Since the base was mounted upside down under the table, the torque turned the router out of it's base. I inspected it for damage and not seeing any I mounted it, properly this time, and turned it on to see if it was alright. To my absolute relief it turned on. Relieved I switched it off and went to bed as it was late.

The next time I wanted to use my router to round over a jig base I was making, there were a whole lot of sparks and it tripped our earth leakage system. I then realised that something had indeed been damaged in the fall. :frown::crying::crying::crying:

The router details are:
Rockwell
Model 63458 Type 1
Heavy Duty Router
220v AC-DC 4.0A 850W 22000/min
(See attached photo)

I have now stripped part of the router and found that the on off switch was cracked and I will have to replace it, but that was clearly not where the sparks were coming from, nor the reason that our power tripped. On further inspection I found a broken piece of a "spring".

Looking deeper into this I found it is a brass spring that is circular and attached to a cable and is supposed to be located around the brass inner end of the bush housing. Sorry I cannot post a photo. I am unable to remove the top part of the housing. I have searched high an low on the internet and have found the part but it is not available. The image from internet is a very small low resolution image s per the last attachment. I think I may have to go to a power tool repair specialist to see if they have an alternative part or solution.

In addition to the broken spring connector, there is a green electronic item which I have never seen before and am unable to identify. I am not sure if it is a fuse, a capacitor or some other electronic component. It seems to have some kind of heat damage (the second image) but my multi meter shows there is still continuity. It would be great if anyone on this forum can identify this part. I have attached photos of the front and back of this part.

Thanking you all in advance for any assistance you can offer.


Doug
 

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Discussion Starter · #2 ·
Sorry when I said bush housing above, I meant brush housing. I have found decent images of the brush and brush housing on the spares pages for Porter Cable routers (I did manage to determine that the Rockwell power tool business was bought by Porter Cable.) The broken spring connector is supposed to encircle the left end of the attached brush housing providing electrical connection and retaining a washer. The only way to attach the spring connector would be with the end of the motor detached which I think would need a puller tool that I do not have.

Many thanks once again.

Kind regards
Doug
 

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Welcome to the forums N/A...
 

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G'day Doug and welcome to the forum.

Can't help with your query, however.....Not electronically endowed.....
 

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@Douglas Reid

I think your green thing is a choke/filter used to minimize interference that may be generated by the router to other electronic equipment. The brushes/motor generate a minor amount of RF and would bother things like TV's and radios. Sort of like noise suppressors that used to be installed in vehicles. A capacitor or inductor may be used to do the suppression.

The spot on the back is likely where it was "glued" to some part of the router and broke off in the fall.

Some equipment has a ferrile wrapped around the power cord to filter the spurious radiation...you've seen this on some power cords and USB cables, chargers, etc...

Do a quick image search for "RF choke"...
 

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Welcome to the forum Doug. Interesting 1st post and I suspect Nick is correct. Porter Cable may be your best bet in getting any information on replacement parts. I have a number of cherished tools that were passed on by both my father and father-in-law. Would be great to see a picture of your table saw as it sounds far different than those I've seen from the past.
 

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Greetings, Douglas and welcome.

There are a few of us from south of the Limpopo on the forum. Don’t know where you live, perhaps you could take the time to complete your profile. A lot of the members use avatars (I think it is a North American thing, we are more straightforward), so your name comes up as N/A, and some of the guys are sticklers for form around here.

That router is before my time in routing (+40 years), but I am sure others here will know the model. What Nick says sounds right about the interference suppressor - the semi-visible coil reminds me of a choke. If so, it will not be necessary to the running of the motor, and unless you (or your neighbours) use A.M. or shortwave radio, it is unlikely to be of consequence. The suppressor on the alternator of my elderly Corolla disintegrated, and the agents for Bosch Auto parts do not even recognise the part, far less stock it. Makes no difference to the radio operation, even on A.M (LM radio in Jhb).
If your multimeter has an impedance range, check whether you get a reading across the terminals (in mH or possibly microHenry). If so, it is a choke, and functional.
 

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Not too sure about the spring... ones that I've looked at - the only spring is the one attached to the brush itself. Perhaps it's just their way of making the connection to the brush holder?
 

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Excellent first post. Welcome. I wasn't certain about the age of the router, however, it may be that by the time you have it repaired, you may have spent nearly the cost of a new router with speed control. I think the others have identified the parts pretty well. A dropped router is often toast. The Porter Cable and DeWalt both use threaded cases to adjust router height, and I don't like the slack in either.

When I was a kid, we had a carpenter who rented a room at our old house and he had a great talbe saw (don't recall the brand, but probably about the same era as yours. He did a lot of finish work and I spent two summers apprenticing/assisting him on job sites. His son was a contractor on custom homes. I can still hang a perfect door every time, we sure did a lot of them. Home reapair on our pre 1913 farm house was a constant source of DIY work.
 

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Discussion Starter · #16 ·
Many thanks, I think this is spot on.

@Douglas Reid

I think your green thing is a choke/filter used to minimize interference that may be generated by the router to other electronic equipment. The brushes/motor generate a minor amount of RF and would bother things like TV's and radios. Sort of like noise suppressors that used to be installed in vehicles. A capacitor or inductor may be used to do the suppression.

The spot on the back is likely where it was "glued" to some part of the router and broke off in the fall.

Some equipment has a ferrile wrapped around the power cord to filter the spurious radiation...you've seen this on some power cords and USB cables, chargers, etc...

Do a quick image search for "RF choke"...
Wow Nick I am certain you are spot on. I even located the area of the frame that it was glued to and will glue it back in place as I think it is undamaged. I Googled RF Choke as suggested and while I found none identical, the copper spring that can be seen through the green plastic certainly seems like the RF Chokes on Google.

I did take it to an electrical supply outlet today and they were clueless, but they are an electrical shop, not an electronics shop.

I thank you so much for sharing your knowledge.
 

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Discussion Starter · #17 ·
Thanks and profile completed

Greetings, Douglas and welcome.

There are a few of us from south of the Limpopo on the forum. Don’t know where you live, perhaps you could take the time to complete your profile. A lot of the members use avatars (I think it is a North American thing, we are more straightforward), so your name comes up as N/A, and some of the guys are sticklers for form around here.

That router is before my time in routing (+40 years), but I am sure others here will know the model. What Nick says sounds right about the interference suppressor - the semi-visible coil reminds me of a choke. If so, it will not be necessary to the running of the motor, and unless you (or your neighbours) use A.M. or shortwave radio, it is unlikely to be of consequence. The suppressor on the alternator of my elderly Corolla disintegrated, and the agents for Bosch Auto parts do not even recognise the part, far less stock it. Makes no difference to the radio operation, even on A.M (LM radio in Jhb).
If your multimeter has an impedance range, check whether you get a reading across the terminals (in mH or possibly microHenry). If so, it is a choke, and functional.
Hi Biagio

Many thanks. I do apologise profusely about my profile not being done, but I have done it now. I did check it with my mulitmeter and there is a small impedance.
 

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Discussion Starter · #20 ·
Thanks and references to table saw

Welcome to the forum Doug. Interesting 1st post and I suspect Nick is correct. Porter Cable may be your best bet in getting any information on replacement parts. I have a number of cherished tools that were passed on by both my father and father-in-law. Would be great to see a picture of your table saw as it sounds far different than those I've seen from the past.
Many thanks. I tried to post a link to some great photos online, but as I do not have 10 posts yet I couldn't. If you search for Tauco table saw and follow the link to Pintrest with the title "TAUCO Export Corp. - Model 34-160, that will then take you to vintagemachinerydotorg.
Mine is identical but not resprayed like the one above. I also have what I think is the original mitre gauge. Whilst it has been accurate enough for my needs until now, I will be building a crosscut sled and 45 degree mitre sled for better accuracy, just as soon as I can get some plywood in this lock down.
 

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