Hi Ernie, those resistors look to be in good condition. When I rebuilt my Lister generator I spray painted the resistors with a black exhaust manifold paint, looked good and stopped them from corroding.

Bob

Good day Ernie, a very interesting question you have posted. You want to fit an AVR to a generator that outputs both 380 volt 3 phase at 50 Hz and also 220 volts at 50Hz. Your generator stator is wired in a Y configuration with the three phase coming off the three legs of the Y but you also have a fourth slip ring on the stator that comes off the centre of the Y, your 220 volts will be between that centre tap and one of the outer legs of the Y. I have never seen an AVR that could control both three phase output and single phase output, I am not saying that such a unit does not exist but if it does it might be very expensive.
I am curious to know why you want to fit an AVR, do you run a lot of very sensitive electronic devices? I ran a ST2 Generator with a single phase 7 KVA Brush generator for many years in Northern New South Wales, Australia, under no load it was dialed in to produce 240 volts at 50 HZ, at full load it would produce 235 volts at 49.7 HZ, not bad for a fifty year old generator set. I ran computers, TVs and all household electrical appliances off this unit without any problems.
Personally, I would replace the old selenium rectifiers with modern silicon rectifiers and then adjust the wire rheostats to get as close to your desired voltages as possible, check that the governor mechanism is working correctly and leave it at that. If you have sensitive electrical appliances, feed them off a UPS which will stabilise the voltage supply to those items.

Hope this helps,

Bob

No wonder these flywheels are so difficult to remove if Butch is recommending urine rather than Loctite. well done guys, Hugh is back in business!

Bob

I love doing jigsaw puzzles, don`t remember ever having to make any of the pieces though.
I hate having to make nuts and bolts, are any of them high tensile? How will you be heat treating them?

Good luck with it, I`m sure it will be another triumph.

Bob

Hi Stef, Starfire came up with a very inventive way of doing emergency repairs using just hand tools and what was available locally. Hugh is probably looking for a more permanent and long lasting repair. I wonder what Starfire would have done about the damaged taper roller bearings.
I recently had to replace a pair of TRBs in a Cooper vintage engine, replacements were only available in the UK at nearly 500 pounds each. I machined the casings to take much more modern TRBs at a fraction of the cost.

I don`t envy Hugh trying to do this sort of work in the subzero temperatures where he lives.
Good Luck.

Bob

Good output.14.5 amps if you run 240 volts, nearly 32 amps if you run 110 volts. Here in Australia the only appliance that would require that amount of juice is a large electric hot water cylinder. I will be very interested to know what she maxes out at.

Bob

Hi 38ac, I definitely had serious wear on that end of my camshaft. I put it in the lathe and turned the shaft down to fit the next smaller size bush.So I now have an original CS with a metric oilite bush at that end. I also had a lot of wear in the governor weight pivot pins, I reamed them out to fit the next sized high carbon steel rod I could find.
I suspect that some of the wear problems I found were due to poor maintenance by previous owners or the amount of hours it had done.

Bob