VW Generator Rebuild part 1

This is the dis-assembly of a 1960's era generator.  I first planned on rebuilding this unit to save some cost on an expensive replacement.  However I can not find all the parts I think I am going to need.  This unit sat for about 10 years in a car, the inside was covered in cobwebs, figured it was safer to clean it up before trying to use it.

First the casing.  The strap around the terminals has already been removed in this picture.  also note that the woodruff keys on both shafts have also been removed.

Next is the pulley side of the generator

The two screws run the length of the generator, so the nuts on the rear need to be removed first.

Once removed you can pry/tap the front cover and internal magneto out.

A woodruff key will fall out.

With a screw driver I was able to remove the other cover once the terminals were removed.

Before the wire brush

After a wire brush

There are 2 screws on the outside of the case that remove the 2 wire "packs", but I was unable to get either screw to break.

I am unsure how the coverings affect the generator, nor am I able to source new ones.  I have found replacement bearings, brushes and pulleys.  I did find this site to source a reasonably priced ($50) refurbished unit.  Most VW sites want over $100 for a refurb unit.  I will probably just replace this for now, and later upgrade to the alternator once funds allow.

If you come across this post feel free to leave a comment if you know of a site to source spare parts for these generators.

If I find the parts, I will post a part 2 on the re-assemble. (I wouldn't hold my breath at this point.)