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I just started restoring a Lionel #8 and would like to replace the brushes. I didn’t realize until I took it apart that the commutator was inline with the shaft and the brush face is curved versus being flat and perpendicular to the shaft. I wanted to know how do you shape the brush so it’s concave shape? Do they make them pre-shaped? Do you use them flat and run them in? Do you file them? What is the correct brush? I see 2-17 on Hennings and brush 75 on Olsens parts diagrams. Thanks in advance for your help.

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2-17 is correct. They will 'seat' themselves as running time is established.

PLEASE NOTE!!! If you are going to run the old trains (pre-war), take the time to run a bead of epoxy around the back side of the copper commutator where it butts up against the wiring. It is especially critical on horizontal commutators such as the # 33, 38, 42, 53 etc.  This will save you agonizing over paying $50 - $75 to have the armature repaired due to a segment coming loose and getting ripped off by the brush.  Harry 

Rich Wiemann posted:

Thanks Rob for the feedback. Sounds like you may have experienced your own armature/commutator self destruction. 

Have you applied epoxy yourself? Any concerns with the armature being out of balance, if not applied evenly?

Sure have.  Balance is not a factor... too little weight differential and too close to the shaft to make a difference.  You'll want to be neat and even all the same.

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