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Warp9 brush replacement Q & A

1212 Views 2 Replies 3 Participants Last post by  piotrsko
Thought I' start a thread specifically on Warp9 brush replacement to see if others are having similar experience with life, etc.

I have just replaced the brushes in my eMiata at 24,000 miles.... I live in a dry dusty place (Santa Fe, NM), and generally drive the car pretty hard in urban/suburban situations with a fair amount of 500-800amp accelleration and *some* 10-15 mile highway driving trips as well as *some* dirt roads when driving to client sites as I sell Solar...

My decision to replace brushes was driven by the fact that SOME of the brushes wore down significantly more than others, and on the most worn ones the springs were almost touching the brush holders.

Brush replacement itself was pretty easy, except that in my build I had to remove the engine bay battery box to get to the brushes. I have the brushes in, and just applied a 12v battery to spin the motor to seat the new brushes under light load.


1. how many miles did YOU get before brush replacement? maybe tell a little about how you drive, and environmental conditions...

2. how long did you run motor on 12v to seat new brushes? How do you know when you're 'done', and ready to run under normal loads?

3. how much current does YOUR motor pull, spinning transmission in neutral, running on a 12v battery? I was surprised mine started at 50amps, but I guess that's what is takes to run the internal fan at 12v?
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Bump this thread. Looking for recommended brushes and suppliers.
I had an issue with the non insulated brush wires shorting to the WARP0 frame and metal/rubber port cover (arced thru the rubber).
This went unnoticed until the Zilla controller finally gave up. Manzanita were marvelous at repairing the controller.
Dont really have a good data point for the miles/brush wear. The motor was used with supposedly new brushes when first installed and has been used in a S10 (untracked miles) and now a VW Doka (aro 3000 miles) but looking to replace them with ones with insulated wires to avoid a repeat of the frame short problem.
Kostov doing 450 amps at 196 v for 3 miles @6%.

Gonna be iffy unless sleeved in a heatproof insulation. Normally they are short enough to not cause issue. Dirt roads and dusty weather in deserts cause a silicon enhanced wear. I got 15,000 so far on my Kostov in Reno, but have 2 spare sets. When the spring gets close to the holder notch bottom, youre in replacement territory. Got my replacement sets from helwig @$600 a set.

Major used to say 40 hours for seating. comm will be bright straw in an even pattern

50 amps @12 v is 600 watts so 3/4 hp kinda. Not bad for a 11" kinda horrendous on a 4".
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