Rewinding DW788 motor

[Raffy]

Just to share my experience rewinding my DW788 motor, saving me at least $300 + shipping per motor replacement. I have 3 units of DW788, but 2 of them developed  motor related issues after 2 years of using it. I cannot afford to buy new units nor new motors. I tried a number of rewinding services shops, but they would not rewind my motors. I got no option but to rewind it myself. Thankfully, after many weeks of studying motor rewinding basics via youtube, I figured out how to rewind dw788 motor. Now have all units working like new, not to worry again about motor related issues. Hello from Manila!

[Gary Beasley]

Could you post a few links to the better videos youve found?

[Raffy]

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Updated: Sept 8, 2021
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I watched lots of youtube videos, i will check the links and post it here soon. But prior to rewinding DW788 motor, here are the recommended steps to know.

1. How to disassemble/assemble DW788. This is a very important step. Gain some experience and confidence that you can properly deep dive into parts of DW788. Thankfully videos abound in youtube.
https://www.youtube.com/watch?v=_6KJbyZQwko
https://www.youtube.com/watch?v=x42jZgEAUwM&t=506s
https://www.youtube.com/watch?v=Y9xdJ8L-teg


2. Basic knowledge of how motor works. Particularly AC motors. Get familiar with parts of the motor and terminologies.
https://www.youtube.com/watch?v=CWulQ1ZSE3c



3. You need tools, multimeter tester, proper size wrench, screw driver bits (philips, flat, star, hex), pliers, etc.
https://www.youtube.com/watch?v=HqxH_TGlntw

Don’t be confused with the language, just look at their actions, tools, etc.

4. Be sure it’s a motor problem. It’s  no joke to disassemble the motor, only to find out it’s  still working.
https://www.youtube.com/watch?v=HNJZhPHdHhw
https://www.youtube.com/watch?v=lmjFzukDhqI

5. If it is motor, watch videos how to remove armature and how to test armature for failures in its winding coils. Do not rewind unless you know how to test armature. You will use the same skills after rewinding anyway.
https://www.youtube.com/watch?v=GDKZBBmvJiI
https://www.youtube.com/watch?v=l9MIpaIgEiw

6. Watch videos who have rewinded motors, particularly armature rewinding. Need not be DW788 motor but get an idea, see how to terminate the coils, etc.
https://www.youtube.com/watch?v=l9MIpaIgEiw&t=53s
https://www.youtube.com/watch?v=Gy4rtgvd9Y8

7. Prepare your materials like Wire gauge, I used AWG 27. Magnet wire. Insulating varnish, cotton strings. See videos how to apply insulating varnish after rewinding.
https://www.youtube.com/watch?v=v2YaSLWKOQE
https://www.youtube.com/watch?v=n5XcGlvlW5c
https://www.youtube.com/watch?v=9L1wJVItwN4

Don’t mind the native language pls. Just see how to do apply varnish.

8. Test..test…test.

[Norm Fengstad]

your amazing