Repair, Rewind, Rebuild
Electric motors fail in predictable ways — bearings wear, windings degrade, shafts score, rotors lose balance. The question for the operator is never whether to act, but whether the right action is a targeted repair, a full rewind, or a complete rebuild. We do all three, across all three of our specialties — commercial, marine, and industrial — from fractional horsepower through 2,000 HP.
A rewound motor is only as good as the process behind it. Cut corners on insulation, skip the VPI, don't surge-test, and the unit lasts six months instead of twenty years. We run a disciplined, repeatable process that extends service life as close to new as the casting will allow — and we document every step so you can audit the work.
Three Service Tiers
- Repair — bearing replacement, brush service, shaft work, targeted electrical repair. The fastest option for motors that are otherwise in good condition.
- Rewind — full winding replacement when insulation has failed or the motor has been overheated/flooded. Core burn-out, rewinding to spec with Class H insulation, VPI impregnation, testing.
- Complete rebuild — full tear-down, rewind, bearing replacement, shaft and housing restoration, dynamic balancing, reassembly, and full-load testing. For end-of-life motors where the casting and laminations are sound but everything else needs renewal.
Our Rewind & Rebuild Process
- Incoming inspection & test — resistance, megger, surge. Written diagnostic report identifying root cause.
- Tear-down & core burn-out — controlled temperature burn-out oven strips old windings without damaging the core lamination.
- Core test — core-loss test to verify lamination integrity before reassembly.
- Rewinding — new copper wound to factory specification or better, using Class H insulation as standard.
- VPI impregnation — vacuum-pressure impregnation with epoxy resin to eliminate voids and maximize dielectric strength.
- Balancing — dynamic balancing on our 2-ton capable stand.
- Testing — full surge test, hipot test, no-load run, and full-load test where applicable.
- Documentation — comprehensive test report for audit or warranty purposes.
Motor Types & Ratings
| Category | Range / Detail |
|---|---|
| AC induction motors | Fractional HP through 2,000 HP, single and three-phase |
| AC synchronous motors | Including brushless and salient-pole |
| DC motors | Shunt, series, compound, and permanent-magnet |
| Wound-rotor motors | Slip-ring service, brush-gear, and rotor resistance |
| Marine-duty motors | Sea-rated insulation systems, IP-rated enclosures |
| Voltages | Low-voltage through 4,160V medium-voltage |
Marine Electric Motor Rewinding
Marine motors live in the harshest environment any rotating equipment sees — salt, humidity, heat, vibration, often all at once. Our marine rewind specification uses marine-grade VPI resin, anti-corrosion coatings on exposed connections, and sea-rated insulation systems. We document everything to ABS and DNV-GL standards when required.
Motor down? Call (718) 768-1136 or contact us.