This furling system came to us non-responsive. Upon opening the drive unit, stuck brushes and a cracked brush holder were found. With the brushes not contacting the commutator, the motor would not engage. After deeming the holder non-repairable and parts non-existent, we turned to 3d printing. New brushes were ordered, the holder was 3D scanned and modified to fit off the shelf brushes, and installed.

Drilling cap to through bolt new holder, improving the design from the one-time use retainer pins to a serviceable design.

Final fitting of new internals.

Through bolted holder to brush cap

Reinstalled in housing, with a fresh coat of paint for a proper installation.