Ok talked to a few people who’s opinions I trust and while a lathe would be the most ideal, you could use a fine file to knock the chunks off and then finish it with some Emory cloth and be on your way.
Thanks @Tim Appreciate the help on this. I've replaced starters, but haven't ever tried to repair one. Thanks @Dedsoto This might be a good solution since I don't have a lathe.
While waiting to hear back from the builder on what I should do, I tried to be as productive as I could. Mounted the seat with the seat slide and belts. For now, the belts are clipped to the seat, which seems OK for the moment. Future state will be much more secure. I also cleaned up the commutator on the starter and ordered new brushes and springs.
I like how compact it is and seems to sit low to the floor. I think that would be perfect in my 29 RPU.
@MojoRacing I had planned to put it on the original seat riser, but it was too tall. Felt like I was sitting ON the car and not IN the car. Thought about sectioning the riser to make it smaller, but that just wasn't working out. I also wanted adjusters on the seat since my wife is shorter than me and needs to be moved forward to drive. Ended up with some cheap sliders from Speedway. I also added a 2" riser on the front, so I'm about 3" from the floor to the bottom of the seat in the front, and 2" from the floor to the bottom of the seat in the back. It also slides at a bit of an angle (up) so as you slide forward the seat moves up as well. Turned out pretty good. Still trying to calm myself until I can talk with the builder, so I'm doing what I can to move forward without stressing myself out...
Talked with the builder today. He thinks the resistance to rotation by hand is O.K. Starter ****ping out was the problem, so I'll get the starter put back together with new springs and bushings and see if it's up to the task. I don't think I'll have the parts to do that before this weekend, so it will have to wait until I'm back from a week long trip to get it back together...oh well.
So I could use some help with my starter. I cleaned up the stator (if that’s what it’s called) and replaced the brushes. All of the copper contacts on this are connected electrically. Seems like it would be shorted? Any thoughts, ideas, or guidance for this old **** would be appreciated!!!
You have to remember that engine has compression. That’s going to give you resistance turning it even with the plugs out
you need to cut down the insulators between copper segments, years ago before I got a commutator cutter I used to use a hacksaw blade 32 tooth cut down to about 8ins and taped a handle so I wouldn't cut my hands, it will remove the insul material easily
Thanks for the input, guys! Looked into this more last night and I think I figured it out. I was only looking for continuity between things. Turns out that I should be looking at the actual resistance numbers. My multi-meter will beep even if resistance is low. I checked resistance between the elements (adjacent and across) and it seems fine. Put it all back together and it spins like a Tasmanian devil! I’ll put it back on the car and try it again later today
Got it back in the car. Spins like a banshee! I consider this a job…done. Next, accelerator pedal setup, brake bleed, etc.