Armature rewinding is precision work — get any stage wrong and the motor won’t perform to spec, or won’t run at all. In this video, one of our engineers rewinds a double armature on a single shaft from a DC motor generator set, showing every stage of the process from coil winding through to final testing.
What’s covered in this video
Our engineer walks through the full armature rewinding process:
- Making diamond form wave-band coils — the replacement coils are formed to the original winding specification.
- Inserting the coils into the armature — each coil is fitted into the armature slots in the correct sequence and tension.
- Skimming & undercutting the commutator — the commutator surface is machined true, and the insulation between segments is undercut to the correct depth.
- Immersing the armature in varnish — the rewound armature is impregnated with insulating varnish to protect the windings and improve durability.
- Drop testing the armature — a final test to check for winding faults before the armature is signed off.
This is the same process our engineers use on the armatures we rewind for customers every week — from single motors to complex double-armature MG sets like the one shown here.
Why this level of detail matters
A rushed or incomplete armature rewind shows up fast — in reduced power, overheating, or early failure. Getting each stage right, from coil formation through to varnish impregnation, is what determines whether a rewound armature performs like new or fails again within months. It’s also why armature rewinding isn’t something to attempt without the right tools, materials and experience.
If your armature is showing signs of wear — burning smell, sparking at the brushes, reduced power, or a motor that won’t reach full speed — it’s worth having it inspected before the damage gets worse.
Talk to the rewinding experts
Find out more about our winding services here.
Call 01179552481 or email enquiries@mawdsleysber.com and get your quote today!
