electrex saga continued

[Steven van Twuyver]

My choices seemed somewhat limited for making a grommet to seal the stator wires into the case. I just don't trust straight RTV for this application. So I spent the entire day running around various surplus stores and electronic stores trying to come up with some kind of substitute. The best suggestion came from an off-road auto parts guy who suggested unsoldering the original stator wires and removing the original grommets, thereby leaving the good original stator still useable. But I want to be able to use it as a drop-in replacement so this was not totally acceptable. What I've come up with I believe will work, looks very OEM and I don't believe it will leak. I fabricated a pair of grommets from 3M rubber/silicone equipment "feet" sold by Radio Shack - about $3.00 for 10. These are intended for things like computers or stereos to prevent marring furniture. I mated a pair together on to its own self-stick adhesive. Then using a single edge razor blade, I cut a pair of retaining grooves which press fit into the case. Then using the razor I squared off both grommets so that the will align smoothly with the case and the gasket. Then I took a small drill the diameter of the wires and drilled five holes in a square with a hole in the middle pattern. I thread the wires throught the holes and everything was very snug. I filled the metal contacting edges with Yamabond and the center gap with black RTV. Now for a test ride. No time until Tuesday. I truely hope this thing puts out more energy than the stock one because it certainly was a lot more work than I anticipated. -svt-