Wincharger 6V Deluxe (Model 37)
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NV-WindmillProject
- Posts: 753
- Joined: Wed Oct 22, 2025 4:49 pm
- Location: Las Vegas NV
Re: Wincharger 6V Deluxe (Model 37)
Amazing work on the 611 Mike 
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NV-WindmillProject
- Posts: 753
- Joined: Wed Oct 22, 2025 4:49 pm
- Location: Las Vegas NV
Re: Wincharger 6V Deluxe (Model 37)
I'm sharing this to help anyone who may be having difficulties removing their Wincharger generator field screws.
My dad and I were unable to remove our 90-year-old field screws using an impact driver, so we decided to drill them out. To do this, we needed to stabilize the cylinder, so I designed and 3D-printed 2 brackets and 4 bracket stabilizers. I routed 2 slots on a leftover MDF board and mounted the brackets on it. Then we clamped the board onto our drill press table and very carefully centered the chuck on the screw head.
We began by using a 3/32" drill bit, which was slightly larger than the width of the screw slot. We used progressively larger bits in 1/64" increments, from 3/32" up to 19/64", making minor adjustments in centering as needed. We chose the 19/64" bit because it is 1/64" smaller than the 5/16" bit used for tapping a 3/8" screw. We did it this way so we wouldn't risk damaging the threads on the field plate.
We owe our success to very careful positioning and drilling. The remains of the screw threads were only 1/16" thick!
To finish off, I cleaned out the hole with a bottle brush and Kroil oil, and put in a new screw to verify the fit.
I hope this helps
My dad and I were unable to remove our 90-year-old field screws using an impact driver, so we decided to drill them out. To do this, we needed to stabilize the cylinder, so I designed and 3D-printed 2 brackets and 4 bracket stabilizers. I routed 2 slots on a leftover MDF board and mounted the brackets on it. Then we clamped the board onto our drill press table and very carefully centered the chuck on the screw head.
We began by using a 3/32" drill bit, which was slightly larger than the width of the screw slot. We used progressively larger bits in 1/64" increments, from 3/32" up to 19/64", making minor adjustments in centering as needed. We chose the 19/64" bit because it is 1/64" smaller than the 5/16" bit used for tapping a 3/8" screw. We did it this way so we wouldn't risk damaging the threads on the field plate.
We owe our success to very careful positioning and drilling. The remains of the screw threads were only 1/16" thick!
To finish off, I cleaned out the hole with a bottle brush and Kroil oil, and put in a new screw to verify the fit.
I hope this helps
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Re: Wincharger 6V Deluxe (Model 37)
Isnt it great learning & using quality tools &?equipmemt from our fore fathers !
You are learning well young apprentice
You are learning well young apprentice
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NV-WindmillProject
- Posts: 753
- Joined: Wed Oct 22, 2025 4:49 pm
- Location: Las Vegas NV
Re: Wincharger 6V Deluxe (Model 37)
Finally, a cool morning for painting! (80 degrees is cool in Las Vegas)
This is the primer coat. My dad and I used Rustoleum primer and wore P95 masks while doing the job.
This is the primer coat. My dad and I used Rustoleum primer and wore P95 masks while doing the job.
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NV-WindmillProject
- Posts: 753
- Joined: Wed Oct 22, 2025 4:49 pm
- Location: Las Vegas NV
Re: Wincharger 6V Deluxe (Model 37)
We woke up this morning to find the temperature at 80 degrees. That means... painting time!
We used Rustoleum High Performance Enamel paint to coat the tower legs and generator housing. We started on the brake drum, but soon the wind came up, so we had to stop for the day.
To paint the generator housing, we had to cover up all the openings because the two field poles were still inside. We covered the big openings with 1/2-inch frog tape and used appropriately sized punches of rubber foam to fill the smaller holes. We also covered the serial number plate with frog tape.
We used Rustoleum High Performance Enamel paint to coat the tower legs and generator housing. We started on the brake drum, but soon the wind came up, so we had to stop for the day.
To paint the generator housing, we had to cover up all the openings because the two field poles were still inside. We covered the big openings with 1/2-inch frog tape and used appropriately sized punches of rubber foam to fill the smaller holes. We also covered the serial number plate with frog tape.
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Last edited by NV-WindmillProject on Fri Aug 14, 2026 1:47 pm, edited 1 time in total.
Re: Wincharger 6V Deluxe (Model 37)
Venn , good quality craftsmanship
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NV-WindmillProject
- Posts: 753
- Joined: Wed Oct 22, 2025 4:49 pm
- Location: Las Vegas NV
Re: Wincharger 6V Deluxe (Model 37)
We painted all the parts for our Wincharger! (except the vane)
The black we used was Rust-Oleum High Performance Enamel, and the red we used was Rust-Oleum Gloss Protective Enamel. There were several types of red at the hardware store, but "Sunrise Red" looked best.
Over the course of last week, we painted the governor assembly, tower parts, mast pipe parts, etc. I also learned a lot about spray-painting metal parts throughout this project, such as: use broad sweeps, don't spray in one spot for too long, don't spray too close or too far from the part.
Photos of finished parts:
To paint the governor springs, my dad devised a mechanical system to get in between the gaps of the springs. Here's what he came up with:
I also 3D-printed custom paint stands for some parts:
The black we used was Rust-Oleum High Performance Enamel, and the red we used was Rust-Oleum Gloss Protective Enamel. There were several types of red at the hardware store, but "Sunrise Red" looked best.
Over the course of last week, we painted the governor assembly, tower parts, mast pipe parts, etc. I also learned a lot about spray-painting metal parts throughout this project, such as: use broad sweeps, don't spray in one spot for too long, don't spray too close or too far from the part.
Photos of finished parts:
To paint the governor springs, my dad devised a mechanical system to get in between the gaps of the springs. Here's what he came up with:
I also 3D-printed custom paint stands for some parts:
You do not have the required permissions to view the files attached to this post.
Re: Wincharger 6V Deluxe (Model 37)
Nice , very nice !
Re: Wincharger 6V Deluxe (Model 37)
Looking good Venn. I'm anxious to see the completed project.
RP
RP
