Craftsman Drill Press

[FrankLee]

Packard Craftsman Motor 115.6963 - Part 3, Cleaning Painted Parts

1. Vacuum any sawdust still on any parts.
   
   
   
   
   
   
2. Scrub all painted parts with Grez-Off and small brushes.
   
   
   
   
   
3. Use Barkeepers Friend if lightly rusted.
   
   
   
   
   
4. Rinse and dry.
   
   
   
   
   
5. Apply paste wax to all painted parts and buff.
   The end frame on the left is waxed, the frame on the right is not.
   
   
   
   
   
6. Drill through and continue to tap the female threads through the end frame for the centrifugal machine screws.
   This will aid in reassembly later.
   
   
   
   
   
   
7. Run a tap through all threaded holes to clean out any dirt and swarf.
   
   

 

[FrankLee]

Packard Craftsman Motor 115.6963 - Part 4, Cleaning the Stator Cover Band

This stator cover band has some light to moderate rust.

1. Scrub the band with Grez-Off and a small brush, rinse and dry.
   
   
   
   
   
   
   
2. Bump out any dents.
   This band has a small dent near the switch.
   
   
   
   
   
3. Mark the dent and draw cross-hairs.
   
   
   
   
   
   
4. Set-up the band and hammers.
   I used an old mouse pad because it has some give underneath the band. I use a convex-faced body hammer on the dent centered on the cross-hairs. Another hammer is used to strike the body hammer.
   
   
   
   
   A couple whacks worked well.
   
   
   
   
   
5. Bend open the four folds on ends and loosely connect the ends together.
   
   
   
   
   
   
6. Insert the band in a bucket, mix-up some citric acid, fill a gallon jug with hot water and pour in the citric acid.
   
   
   
   
   
   
   
7. After an hour or so, pull the band out and lightly scrub with #0000 steel wool and the citric acid.
   
   
   
   
   
   
8. Rinse, dry and wax.
   Far from perfect, but more than acceptable to me.
   
   

 

[Outlawmws]

Once again, very nice documentation work Frank.

One comment on the hammers; never strike two hardened steel hammers together. For the striking hammer a lead or brass hammer plastic face or even a hardwood hammer should be used.,

 

[FrankLee]

Packard Craftsman Motor 115.6963 - Part 5, Cleaning the Small Parts

There are a variety of small parts in this motor. Most will get sonic cleaned.

1. Place all small parts in a jar and run them in the sonic cleaner for a couple rounds. Bearings will get cleaned separately
   
   
   
   
   
2. After sonic cleaning, wire wheel the screw heads and bearing plates.
   
   
   
   
   
3. Wire wheel the acorn nuts and threads of the thru-bolts. Clean the rods with steel wool.
   These were not rusted enough to warrant an acid bath.
   
   
   
   
   
   
4. Flatten any dents in the motor badge.
   
   
   
   
   
   
5. Clean the motor badge, the thermal switch badge and the ON/OFF plate with cleaner wax.
   
   
   
   
   
   
   
   
   
   
6. Clean bearings separately with several cycles in the sonic cleaner.
   
   
   
   
   
   
   
7. When the bearings look clean, use fresh lacquer thinner for a couple more rounds.
   
   

Beautiful! Zero axial play, zero radial play. These are going back in.

 

[FrankLee]

Packard Craftsman Motor 115.6963 - Part 6, Assembly Prep

1. Install the air cone into the fan-side end frame.
   
   
   
   
   
   
2. Tap (4-40) the holes for the thermal switch badge and Install the badge with 4-40 screws.
   The holes do not need to be drilled.
   
   
   
   
   
   
   
3. Insert 8-32 x 1" set screws into the new thru-holes for the cent switch.
   
   
   
   
   
4. Install the switch shield and switch insulation. The set screws will hold them in place until the switch is installed.
   
   
   
   
   
5. Remove the remainder of the old cord.
   
   
   
   
   
   
   
6. Drill (#29) and tap (8-32) the base for a ground screw.
   
   
   
   
   
   
   
   
   
   
   
   
   
7. Insert a new grommet into the base.
   This grommet is a tight fit in the base and the cord will be a tight fit in the grommet.
   
   
   

 

[FrankLee]

Packard Craftsman Motor 115.6963 - Part 7, Assembling Stator and Switch-Side End Frame

1. Set the switch-side end frame adjacent to the stator and install the Klixon thermal switch.
   
   
   
   
   
   
2. Set the centrifugal switch assembly inside the end frame.
   
   
   
   
   
3. Insert the screws into the terminal board and install the paper retaining washers onto the screws.
   The paper washers are not insulators. They simply hold the screws in place during assembly.
   
   
   
   
   
4. Loosen the nuts on the wire terminals.
   This allows some flexibility of the terminal board during assembly.
   
   
   
   Motor Assembly Jig
   
   Because of my unorthodox(?) method of dismantling and assembling these motors, I made this jig to aid in installing the terminal board into the end frame.
   
   The two outboard screws thread into the terminal box. The two inboard screws are loose in the cross bar and thread onto the wire terminals. This keeps the terminal board mounting screws aligned for installation.
   
   
   
   
   
   
   
5. Tilt up the end frame to the stator and install the inboard screws of the jig onto the terminal screws.
   
   
   
   
   
6. Install the outboard screws of the jig into the terminal box cover screw holes.
   
   
   
   
   
   
7. Pull the two inboard screws of the jig and start the two terminal board mounting screws.
   
   
   
   
   
   
   
8. Remove the jig once the screws are started and tighten down the terminal board mounting screws.
   
   
9. Tilt the end frame and stator up on end.
   
   
   
   
   
   
10. Observe and adjust the wiring.
    All wires should enter the base in the same opening.
    
    
    
    
    
    
    
11. Adjust the stator on the end frame so the thru-bolt slots align with the end frame holes.
    
    
    
    
    
12. Install the centrifugal switch onto the set screws.
    
    
    
    
    
    
13. Remove one of the set screws and install a cent switch mounting screw.
    
    
    
    
    
    
    
14. Remove the other set screw and install the other cent switch mounting screw.
    
    
    
    
    
    The switch side end frame is installed onto the stator. The original wiring is intact and in great shape.
    
    
15. Set the stator/end frame assembly onto the motor jig.
    
    
    
    
    

 

[FrankLee]

Packard Craftsman Motor 115.6963 - Part 8, Installing the Rotor and Fan-Side End Frame

1. Heat one of the bearings for about five minutes and slide it onto the fan side of the rotor.
   
   
   
   
   
   
   
2. Insert the rotor into the stator.
   
   
   
   
   
   
3. Install the fan-side end frame onto the rotor. and align the thru-bolt holes.
   Note that there are three "tabs" on the end frame. The tab above the vent hole is the top.
   
   
   
   
   
   
4. Install an acorn nut on each thru-bolt and insert all through the assembly.
   
   
   
   
   
   
5. Install the remaining acorn nuts and tighten.
   
   
   
   
   
   
6. Flip the motor and install the motor jig onto the fan side.
   
   
   
   
   
   
7. Heat the other bearing for five minutes and install on the switch side.
   
   
   
   
   
   
8. Seat the bearing with a small pipe.
   
   
   
   
   
   
9. Tighten the terminal nuts and install the terminal box cover.
   
   
   
   
   
   
10. Remove the motor from the jig, set it on its side and spin the rotor to verify no hang-ups.
    
    
    
    
    
    It's ready for a power test. I do this now in case I have to open the motor again.
    
    
11. Carefully connect a temporary power cord.
    
    
    
    
    
12. Hold the motor firmly and flip on the switch for just a second.
    Note: The bearings are not yet lubricated, so it's much louder than it will be.
    

 

[FrankLee]

Packard Craftsman Motor 115.6963 - Part 7, Installing the Stator Cover Band

So, this 3450 rpm motor seems to be an oddball. I would have expected it to be the same size as the 1750 rpm motor, but it is smaller. The rotor shaft is ~12" versus ~12-1/2". The rotor body, the stator and the stator cover band are all narrower, but the end frames appear to be the same size. All photos I could find of 115.6963 motors look to be the same size as the 115.6962. This 115.6963 appears to be the same size as a 115.7429.

Below are some comparison photos of this 6963 band and my 6962 band.

Why does it matter?

Notice that the rivets on the 6963 band are closer to the edge of the band. The back of the rivets overlap and interfere with the tabs on the end frames. This means that the back side of the new blind rivets must be as flat as the original rivets.

1. Remove the rivets from their nails and shorten them to ~3/32".
   
   
   
   
   
2. Attach the badge using the shortened rivets and pop out their nail heads.
   
   
   
   
   
3. Strike the back side of the rivets with a center punch to splay them open.
   
   
   
   
   
   
4. Flatten the rivets with a pin punch.
   
   
   
   
   
   
5. Place the motor in the center band with the wires routed and the badge oriented appropriately.
   
   
   
   
   
6. Hook the ends of the band together and center the opening of the band over the base bolt holes.
   
   
   
   
   
7. Flatten the fold-over tabs.
   
   
   
   
   
   
8. Test fit the base to verify spacing and orientation.