Ignition coil rebuild?

[D S.]

I thought I vaguely recalled a discussion here about ignition coils being able to be rebuilt but could not locate it via the archive search. Is there a source or sources who can rebuild them without damage to the metal case and tops on Delco-Remy ignition coils? If not is there a source or sources who sells original D-R ignition coils?

Thanks,
Scott

[Ken A.]

Re: Ignition coil rebuild?

The coil was like a spark plug, i.e., a pitch item-not designed to be rebuilt. In addition , the oil inside contains PCBs, and was filled under vacuum. This is not something the average shop should attempt to do.

[Terry M.]

Re: Ignition coil rebuild?

I knew an individual who rebuilt coils for antique (that means older than any of us here) automobiles. Both he and his son (who was my age, and how I came to meet him) have passed away, and I don't know what happened to the old machines he had.

I post this only to point out that some coils can be rebuilt -- as to whether ours are among those is another story.

My understanding is that Ken's cautions about the fluid in the coils is spot on. That said PCBs, while illegal to produce, are not all that hazardous. One should use proper precautions in handling them. They do cause cancer if inhaled or ingested, and can be absorbed through the skin. Use heavy duty chemical resistant gloves, do not smoke or eat around the material, and dispose it as a hazardous material. If you get any of the material on your clothes they must be disposed of properly as well. How one would get some more fluid to replenish a leaking coil is a mystery to me, although combining the fluid from several coils comes to mind.
I also don't know how one would open a coil, or reseal it after opening it. That may be the most important part.

In my former life I handled PCB containing fluids as part of my job, and received regular training in their use. These materials are very persistent in the environment, and are not to be handled without training. These notes DO NOT constitute even a small portion of that training -- so do be careful. It is a good thing that the remaining sources of these fluids are mostly automotive coils and fluorescent ballasts.

[D S.]

Re: Ignition coil rebuild?

Sounds like you once worked for the EPA.

[Joe L.]

Re: Ignition coil rebuild?

I thought I vaguely recalled a discussion here about ignition coils being able to be rebuilt but could not locate it via the archive search. Is there a source or sources who can rebuild them without damage to the metal case and tops on Delco-Remy ignition coils? If not is there a source or sources who sells original D-R ignition coils?

Thanks,
Scott

Scott-----


It's not possible to rebuild a coil using all of the original components. The "can" is pretty much impossible to remove and re-use without destroying it.

Paul Baker of Goat Hill Products manufactures reproduction coils. To do this, he salvages the top from junk-yard coils of no particular interest to restorers (many of which use exactly the same top as coils which are of interest to restorers) or coils which are "electrically compromised".

Then, he manufactures reproduction cans with the "correct" embossments and assembles the coils using all new "innards". I do not know where he acquires the "innards".

As far as I know, Paul does not otherwise restore coils (although he would probably use the top section of any coil you send him).

[Terry M.]

Re: Ignition coil rebuild?

Sounds like you once worked for the EPA.

Nope. An electric utility. Once upon a time PCBs were added to the transformer cooling/insulating oil to make it more fire resistant. The same reason it is in coils and ballasts. Then came the environmental laws. We, and other utilities, sent many thousands of perfectly good transformers to special landfills solely because they contained PCB laced fluid. The costs were staggering.

[D S.]

Re: Ignition coil rebuild?

Joe, after examining a couple of coils I have I couldn't see how it was possible but I asked anyway. This Paul guy....can he make a 287 B-R look exactly like the originals?

Terry, not to mention the costs of future environmental impacts because of the buried PCBs.

Thanks all!

[Joe L.]

Re: Ignition coil rebuild?

Joe, after examining a couple of coils I have I couldn't see how it was possible but I asked anyway. This Paul guy....can he make a 287 B-R look exactly like the originals?

Terry, not to mention the costs of future environmental impacts because of the buried PCBs.

Thanks all!

Scott------


I don't know if he can make it EXACTLY like the originals but I think he comes as close as you can get. Inspect his work at one of the shows he attends (usually all Pomona, Bloomington, Carlisle, etc.). If you like what you see, buy it from him at the show.

[Ken A.]

Re: Ignition coil rebuild?

Scott-----


It's not possible to rebuild a coil using all of the original components. The "can" is pretty much impossible to remove and re-use without destroying it.

Paul Baker of Goat Hill Products manufactures reproduction coils. To do this, he salvages the top from junk-yard coils of no particular interest to restorers (many of which use exactly the same top as coils which are of interest to restorers) or coils which are "electrically compromised".

Then, he manufactures reproduction cans with the "correct" embossments and assembles the coils using all new "innards". I do not know where he acquires the "innards".

As far as I know, Paul does not otherwise restore coils (although he would probably use the top section of any coil you send him).

Joe,
A "sleeved" used coil is not a rebuilt coil.
In addition, he cannot properly fill a coil with oil, without a vacuum source.
If he were to use the old oil it would be contaminated with carbon & therefore not a good insulator.
Andover used to make coils in the US, but they were generically "wound"
for many apps, not necessarily to GM's specs.
Ken

[Jack H.]

Re: Ignition coil rebuild?

There are several who 'remanufacture' coils, but they keep a low profile and don't cater to end users (qty one jobs). Some of the process is pretty simple, the balance is retained as 'trade secret'.

The process starts by acquiring various Delco Remy coils from scrap yard sources. Next, they're drained of their cooling fluid. That process is child's play, Terry!

Look down inside the center post electrode of a coil and you'll find a flush mount, slot head screw. Remove the screw and the upper electrode contact lifts up/out allowing you to 'pour' and drain the coil of its cooling fluid.

Next, the coil is chucked into a lathe and the crimped edges of the case are either cut away or de-crimped allowing the upper Bakelite tower and its attached transformer assy to be removed from the coil case.

The raw coil transformer assy's are cleaned up, electrically tested for 'profile' (primary/secondary winding configuration, energy transfer characteristics and upper Bakelite configuration) then binned according to specifics.

Now, the re-assy process starts. A 'correct' profile, original Delco Remy transformer assy is selected (hence no need for a GM license). A fresh steel case (yes, they're available in bulk) is mounted on a special holding fixture and the rebuilder selects the appropriate de-boss tool that he's created.

The de-boss tool is inserted into the raw blank case and the appropriate case ID marks are re-created by the de-boss tool being hydraulically expanded inside the case with the case held in its supporting surrounding fixture.

Last, the freshly recreated case is crimped to the hand selected Delco transformer assy, the assy is filled with cooling fluid and a fresh upper electrode is installed and screwed in place to seal the coil. Job done!

[Joe L.]

Re: Ignition coil rebuild?

Joe,
A "sleeved" used coil is not a rebuilt coil.
In addition, he cannot properly fill a coil with oil, without a vacuum source.
If he were to use the old oil it would be contaminated with carbon & therefore not a good insulator.
Andover used to make coils in the US, but they were generically "wound"
for many apps, not necessarily to GM's specs.
Ken

Ken-----


I wasn't referring to a sleeved coil. Paul Baker does supply such sleeves and does sleeve coils, but that's not what I was talking about. As of the last several years, he "rebuilds" coils as I described and as Jack describes in more detail.