Repairing a duff throttle pot

[bobfather]

As many of you know these throttle pots are not built for the heat of a TVR engine bay. I've seen several images of failed pots and in most cases the wires look too rigid as though the insulation had hardened. I've also noticed that the wires look particularly vulnerable as they exit the pot. I acquired a failed pot to experiment on. As expected the test showed an intermittent open circuit on one wire and looking more deeply that open circuit was as the brown wire entered the pot. The insulation was holding the wire in place so the fault wasn't obvious visually.

Anyhow,

I used a Dremel to grind out the area of the broken wire. I was only able to machine out 1.5mm before hitting the edge of the resistor track. That exposed a brass crimp connector, the wire had sheared at the crimp.



Wrapping a new wire around the brass crimp provided plenty of contact for a solder joint.



The other two wires were replaced by soldering on new wires close to the pot because the insulation was very brittle. Black epoxy resin was used to insulate and support the wires to prevent future stress ate the exit of the pot



Rewire to the original plug and add some trunking for good measure



Bench test shows it to be working exactly as my original.

[bomb]

Top work Bobfather.

[Penelope Stopit]

Great fix, nice.
Not meaning to sound bhy in any way but...There is now plenty of heat-shrink on the market that is adhesive lined and the adhesive does make a much better seal of the joint

Edited by Penelope Stopit on Tuesday 10th April 18:10

[Belle427]

This is pretty robust stuff too that takes a lot of heat.
https://www.amazon.co.uk/10mm-Black-Heat-Resistant...