D80 2..0

[lesinutah]

Hey
I have mentioned recently my rebuilding 2 d80s. It was 2 days ago i finally had first one all together and finished. I thought it was finished but i was wrong.
I turned it on it worked but didnt sound right. It felt like the fan was hitting something. It turns out armature fan sas grazing 2 wires from headlight in motor housing. I fixed nicks in wires using heat shrink. I also fixed it so the wires wouldn't get hit again.
The problem is wires staying in safety switch. I took the back cover off the safety switch.

 

[lesinutah]

2

So you see first pic is safety switch and second pic is copper piece from safety switch. I was wondering if i could pull out copper tabs and solddr wires to them and reinsert in safety switch. I have back ill put back on just gluing it back together.
2nd question on power switch it has 3 ground slots and 3 white slots. Couldn't i take all 3 grounds solder together while soldering a 4th wire. It would be 3 soldered and end result 1 wire coming out. It would combine all greens to 1 wire. I would do same for 3 whites. So instead of using all 6 slots i would use just 2.
The reason behind this is only 2 wires could come loose.
It has 2 slots for power wires. One power is from headlight power the other goes to carbon brush holders and holds in carbon brushes.
I dont know why anpower is ran to carbon brushes but combining the 2 could arc something out.
So any feedback would be appreciated.
Les

 

[lesinutah]

Yup

I soldered it and it kind of worked. It activated both speeds. I need to rewire or find a bypass i dont know it doesn't like me.
In other news sentria i used avalir carpet cleaner it was nice.
My 560 put new carbn brushes but sounds like front bearing is shot. But that is an easy fix.
Les

 

[lesinutah]

Hello

I just wired correctly with a different switch no power. The 2 power leads i switched might be culprit or bad switch. Im hoping its easy fix.
Les,

 

[lesinutah]

Finally

I could not let it sit. I took of casing and switched leads and it works. I hope to finally have fully rebuilt d80 with 4 roll brush roll with my bag assembly and d80 at full potential and power. Thanks for reading.
Les