Dremel 395 brushes

May I please pick the collective brains on this one. I am trying to replace the carbon brushes on my Dremel. I have new brushes but the original brushes had springs attached that were about 1.5 cm long. The new ones have springs that are nearer 2.5 cm long. Try as I might I cannot get the new springs to compress sufficiently to allow the securing caps to be screwed down. The springs just bend over and get jammed. Unfortunately I only managed to recover one of the old springs the other getting bent and stretched when I removed the old brushes.

So far I have managed to mangle two new springs in my frustrated attempts to fit them. Does anyone have a bright idea how I might fit these? Am I missing something blindingly obvious? I have looked at t’tube without success. There are plenty of videos but none that I can find successfully fitting these longer springs.

As an aside does anyone have any idea why the length of the springs was changed? I am assuming I have the correct brushes and springs. The part number is correct on the pack with reference to the Bosch Dremel website.

Any advice gratefully received before I go completely mad with the things. Thanks Allen

Can you not shorten the spring to the same length as the old ones ?

I had thought I might have to try that Roy. They are tapered so one end is fitted into the cap whilst the other is secured onto the brush. Time to get out my copy of Workshop Practice on springs I guess! Allen

Hi Allen

I was looking back over some early MEWs and there was an article on a spring loaded centre locator for the drilling machine. The spring used was from a retractable ball point pen. These are about the correct diameter and I have used them in the past on projects and the pressure is quite strong. May be worth a try.

Regards

Stuart

Thanks for the suggestions gents. I tried cutting down a new spring and after a fiddle I did manage to get it in. The pen spring idea is a bit more complicated because the top of the spring has to be a larger diameter so that when the securing cap is fitted the spring engages with a brass conductor. I also tried rewinding the old damaged spring and have it almost the right size so will hang onto it as a spare.

That all said and done it’s still not working so I shall have to explore further to see what other fault there is. Bit of a pain as it means I have to take the brush caps off again so I can open the body again. Oh well, I like a challenge.

Allen