1. If I am doing this removal by myself I loop some 1/4" nylon cord through the gear activating mechanism and tie it off to something above to keep the starter from crashing to the floor.

2. I rebuilt my 6 volt stomp starter (new bushings, brushes, springs from O'Reilly's and switch) 40,000 miles ago and it has been running on 12 volts with no problems since. I drug a blade made from an old piece of hacksaw blade through the gaps between the commutator segments to remove the mica insulators to 1/32" or so below the segments. Then I cleaned up the commutator with some 120 grit sandpaper (the maintenance manual calls for "No. 00 sandpaper", but I don't know what that is; DO NOT USE Emory cloth - the residue conducts electricity).


'57 GMC 102, Original 347 V8, HydraMatic, 3.08 rear gear, added A/C, disk front brakes, HEI, AFB carb, '98 Honda Black Currant paint. T-boned and totaled 10/12
'52 GMC 152 Stake Bed, Original 228, SM420, added A/C, HEI, disk front brakes, '67 Chev 3.55 rear gear. Gets used as a real truck.