Delco Remy 1911095 Condenser Rebuild

The discrepancy:
The wire terminal on the generator armature lug of my 62 Cadillac was frayed. I decided to repair it before I 
found myself on the side of the road.

While replacing the terminal I bumped the radio noise suppression condenser. Sure enough, the wire fell off. #$*!!
They don't make .3 microfarad condensers any more. #$*!!

Corrective action:

I put the condenser in the vise.
To keep it from sliding on me I also
put a U-joint clip behind it. Then I
carefully pried open the lip holding 
the orange rubber/felt/rubber seal
with a small screwdriver and 
needle nose pliers.

With the opening wide enough. I inserted an off set pick into the hole of the orange seal to wiggle it out.

With the seal face down. It 
exposes the contact that 
presses up against the inside
of the condenser.

Once separated, you can see where the wire broke.

I removed the solder and broken wire strands from the contact. 
Installed a new wire of the same color and gage through the hole 
in the contact.
Then I spread wires around the radius of the contact.
(Make sure you cut the strands short enough so that they do 
not hangover the lip and short out on the condenser case.)
Carefully solder the strands and contact. I used flux core 
solder and had to polish off the flux to make for a good electrical 
connection.

Once that end was completed. I put the terminal end in the vise and gingerly removed the wire so I could reuse
the original terminal. (This is The Poorman's Off Chassis Restoration. We don't through it out unless it's busted!)
Plus it keeps it looking original. With the wire assembly completed it was ready to be put back together.

Place the condenser between two pieces of angle iron and use the top of the 
vise to keep it from sliding. Gingerly peen of the lip with a small ball peen 
hammer. Carefully! Do not hit the wire.

When I went to test the condenser the battery in the meter 
was dead. You know, I didn't have a 9 volt in stock. After a quick 
trip to the store and some scotch brite to clean the outside and
terminal end of the condenser, it tested OK.  348.7 nanofarads.
Change the decimal place (.348 microfarads) and that's close
enough for government work.

You can use this practice on any condenser.
I saw online that they are selling  rebuilt DR1911095's for about 60 bucks.
If you have any old ones or need one rebuilt hit me up.                                                   ques@tpocr.com

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