Here is the prepared nail, with a section of the phosphor-bronze ready to be cut to size.
Taycol Model Marine Electric Motors
Small Taycol Brush Gear Refurbishment
and here is a little dip I cut in some scrap aluminium to mould the small indentation in the brush...
Well, we make the brushes out of Phosphor Bronze spring sheet - 0.7mm thickness. And we use a rounded-off nail to punch a dimple in the material where required.
...and away I go, knocking a little dip in a brush I cut out earlier...
Finally, I found the answer. Create the dip BEFORE cutting out the brush shape. That way, you get a perfect indentation, and you can cut precisely to get it in the right place...
...and the final result looks just like new...
Oh dear! It seems very difficult to get the dip in precisely the right place...
And here are some successful ones I made afer following this advice :)
