Banjo Horn Repair

[robmog]

Bob here,
Thanks for the kind words.
Mike you have gotten good advice thus far.
First step is to check coil continuity across the spade connectors.
If no go then clean “ignition points”
If no go then across coil itself before points
If no go coil is shorted needs to be rewound.
Use 21 awg coil wire you need about 15-20 ft.
With a hammer and punch move the tabs that secure the coil to the magnet core.
Carefully cut the coil free with the plan to later solder it back in.
Strip the wire from the coil and confirm length, rewind the new wire in place neatness counts!
Re install reversing above steps.
Clean and paint parts then new gaskets and assemble.
From that point getting them to work is trial and error with the diaphragm shims.
It is time intensive but not impossible.
I bet you could bring it to an armature shop and they could wrap the coil for you.
I don’t rebuild anymore, too busy st present
Good luck!

[t6dpilot]

Mike, I will guarantee that your coil is burned out. I have three these horns and they all suffer the same fate. Coming from this industry many years ago, I have seen many contactor coils burned out through too much resistance generated when trying to bring the EI laminations together. I suspect that the heavy coating of rust is to blame and over many years of activating the assembly with a rusty EI, the coil slowly builds up too much heat and finally fails.

I pulled mine apart and plan to send it to a fellow who has a coil winder. Hard to find someone like that who will do it for you though. The wire from my coil mic'd out at .025 or .026 and the coil had 90 windings. Good luck and let us know how it turned out.